Audi RS6 C5 2002-2004 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Audi Model: RS6 Chassis Code: C5 Model Years Covered: 2002, 2003, 2004 Codes Engine Codes: BCY, BRN (4.2L V8 Bi-Turbo) 👋 Introduction Market Position Vehicle...

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Type: Car

Vendor:

Sku: 431092

Tags: 2002 2003 2004 Audi Car Cars RS6 RS6 C5

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Chassis Code:

Model Years Covered:

2002, 2003, 2004

Codes

Engine Codes:

BCY, BRN (4.2L V8 Bi-Turbo)

👋 Introduction

Market Position

Vehicle Segment:

High-performance executive sedan/wagon (Supercar in disguise)

Competitive Analysis

Key Competitors:

BMW M5 (E39), Mercedes-Benz E55 AMG (W211), Jaguar S-Type R

Key Features

Performance Focus:

Legendary twin-turbo V8 power, quattro all-wheel drive, sport-tuned suspension and braking systems, exclusive RS styling.

Manual Value Proposition

Target Audience:

Audi RS6 C5 owners, independent repair shops, performance enthusiasts

📋 Manual Details

Coverage Areas

Primary Focus:

Service, Repair, Troubleshooting, Diagnostics

Secondary Focus:

Maintenance, Specifications, Wiring Diagrams

Page Count

Estimated Page Count:

Over 1500

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Clutch System, Manual Transaxle System, Automatic Transaxle System, Driveshaft and Axle

Chassis And Body:

Suspension System, Steering System, Brake System, Restraint System (Airbags, Seatbelts), Body (Interior and Exterior), Body Electrical System, HVAC

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, inspections

Repair Diagnostics:

Step-by-step repair instructions, diagnostic procedures, troubleshooting guides, component testing

Technical Depth

Depth:

Comprehensive: From basic maintenance to complete engine rebuilds and advanced electrical system diagnostics.

📊 Manual Specifications

File Format

Readability:

Searchable PDF text

Print Quality

Printability:

High-resolution, printable pages

Binding Type

Physical Format:

Digital (PDF)

Paper Type

Digital Format Details:

Optimized for screen viewing and printing specific sections.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4.2L (4172cc) V8 Bi-Turbocharged

Performance

Horsepower:

450 PS (444 bhp; 331 kW) at 5700–6600 rpm

Torque:

560 Nm (413 lb-ft) at 1950–5600 rpm

Fuel System

Fuel Delivery:

Electronic fuel injection (Bosch Motronic ME7.1)

Engine Internals

Bore X Stroke:

84.5 mm x 93.0 mm

Compression Ratio:

9.0:1

Cooling System

Coolant Type:

G12 Plus (or equivalent pink/red long-life coolant)

Lubrication System

Oil Capacity:

Approx. 8.0 liters (8.5 US quarts)

Recommended Oil:

Fully synthetic 5W-40 (e.g., Castrol Edge Professional OE 5W-40)

🔧 Transmission

Standard

Type:

5-speed Tiptronic automatic (01E)

Optional

Type:

6-speed manual (available in some markets/later production)

Features

Drivetrain:

Torsen Center Differential (Quattro AWD)

Fluid Specs

Automatic Transmission Fluid:

G 052 162 A2 (or equivalent ATF meeting VW 501.62 specification)

Fluid Capacity

Automatic Transmission Fluid Capacity:

Approx. 5.0 liters (service fill)

Manual Transmission Fluid

Fluid Type:

G 052 145 A2 (or equivalent synthetic gear oil, e.g., 75W-90 GL-4/GL-5)

📐 Dimensions

Exterior

Length:

4,885 mm (192.3 in)

Width:

1,818 mm (71.6 in)

Height:

1,461 mm (57.5 in)

Weights

Curb Weight:

Approx. 1,860 kg (4,100 lbs)

Gross Vehicle Weight Rating:

Approx. 2,340 kg (5,159 lbs)

Cargo

Trunk Volume Sedan:

Approx. 565 liters (19.9 cu ft)

Trunk Volume Avant:

Approx. 455 liters (16.1 cu ft) with seats up, 1,570 liters (55.4 cu ft) with seats down

🛡️ Safety Features

Ratings

NHTSA Rating:

Not specifically rated for this model year, but generally reflects strong structural integrity for its era.

Active Features

Braking System:

Larger, performance-tuned disc brakes (e.g., 360mm front discs with 8-piston calipers on some models), ABS, EBD, ESP

Passive Features

Airbags:

Front, side, and curtain airbags

Seatbelts:

Pretensioning front seatbelts

💡 Technology Features

Infotainment

Head Unit:

Audi Chorus or Concert radio systems (with CD player), optional navigation system.

Driver Assistance

Stability Control:

Electronic Stability Program (ESP)

Traction Control:

ASR (Anti-Slip Regulation)

Connectivity

Features:

Optional Bose sound system, Bluetooth integration (later models/aftermarket).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 10,000-15,000 miles or 12 months, whichever comes first (refer to manual for specific conditions).

Spark Plug Replacement:

Approx. 60,000 miles (refer to manual for specific plug type and gap)

Timing Belt Replacement:

This model uses a timing chain system, not a belt.

Fluid Specifications

Brake Fluid:

DOT 4 (or specified Audi standard)

Power Steering Fluid:

G 002 000 (or Pentosin CHF 11S)

Known Issues

Common Wear Items:

Coil packs, ignition modules, serpentine belts, PCV system components, catalytic converters, CV joints, automatic transmission torque converter.

Performance Related:

Turbocharger maintenance, intercooler system leaks, boost pressure issues.

Electrical:

Window regulator motors, HVAC blower motor resistor, ABS sensor failures.

📚 Vehicle History

Brand Heritage

Heritage Focus:

Audi's long history of quattro all-wheel drive and performance engineering.

Model Evolution

Rs Line Introduction:

The RS6 represents the pinnacle of the Audi A6 (C5) platform's performance iteration, following the RS2 Avant and S6 models.

Production

Production Period:

2002-2004

Manufacturing Location:

Germany

🏆 Awards & Recognition

Recognitions

Performance Acclaim:

Praised by automotive journalists for its immense power, all-weather capability, and relatively understated yet potent performance.

Ratings

General Reputation:

Considered a 'super sedan' or 'sleeper' performance car of its era, offering supercar-like acceleration in a practical package.