2008 Audi RS4 Engine-Out Service: Crank Girdle Reseal, Clutch, Carbon Clean, and Upgrades
Addressing oil leaks, drivability, and known B7 RS4 weak points in one comprehensive service
The B7 Audi RS4 is a special car. The high-revving 4.2L naturally aspirated V8 delivers a driving experience that modern Audi platforms simply don’t replicate—but at higher mileage, these cars demand careful planning and thorough execution when major work is required.
This 2008 Audi RS4 came to Griffin Motorwerke with a significant oil leak from the crank girdle, along with the owner's clear request to address everything that makes sense, including clutch, carbon buildup, known wear items, and recommended upgrades.
Inspection and Planning
Initial inspection confirmed heavy oil leakage originating from the lower engine, consistent with crank girdle and sealing failure. Additional findings included:
- Cracked upper and lower control arm bushings
- Worn front tires approaching cords
- Aging intake manifold runner components
- Opportunity for suspension and driveline upgrades while fully disassembled
With the scope defined, the decision was made to proceed with a full engine-out service, allowing all major items to be addressed correctly and efficiently.
Engine Removal, Sealing, and Timing Service
Once removed, the engine underwent extensive resealing and preventative service:
- Crank girdle reseal
- Cam girdle reseal
- Rear main seal replacement
- Timing chain service with new chains, guides, tensioners, and hardware
- Valve cover gaskets and associated seals
These are well-known problem areas on the B7 RS4 and addressing them with the engine out avoids repeat labor and future leaks.
Clutch, Drivetrain, and Supporting Systems
With the engine and transmission separated, we replaced the complete clutch system, including:
- New clutch kit and dual-mass flywheel
- Slave cylinder, guide sleeve, pivot hardware, and main shaft seal
- Driveshaft center support bearing
Incremental opportunities were also taken to replace components that are otherwise difficult to access, including sensors, hoses, seals, and the oil separator.
Carbon Cleaning and Fuel System Refresh
As expected on a high-mileage direct-injection V8, carbon buildup was present on the intake valves. While disassembled, we performed a carbon clean of the intake ports and valves.
At the same time, all fuel injectors were replaced with new OEM units, along with seals and intake gaskets. Doing injector checks during a carbon service is smart preventive maintenance and helps prevent future misfire or leakage issues.
Recommended Upgrades and Suspension Work
With the mechanical foundation addressed, we installed several upgrades aimed at improving longevity and driving feel:
- Upgraded intake manifold runner arms
- Front and rear upgraded sway bars
- New front upper and lower control arms
- Street-density engine mounts
These upgrades tighten up the chassis, improve response, and address common RS4 wear points without compromising the character of the car.
Final Assembly, Service Catch-Up, and Road Setup
Before reinstalling the engine, additional items were handled while access was available:
- Oxygen sensors
- Auxiliary radiator replacement
- Heater core hose repair
- Ignition coils, connectors, and spark plugs
- Brake fluid flush
- Full oil service and fluid top-offs
Once reassembled, the RS4 received new Michelin Pilot Sport 4S tires, a road force balance, and a full four-wheel alignment to complete the package.
The Result
The result is a B7 RS4 that’s properly sorted from the inside out. Oil leaks are resolved, driveline operation is smooth, throttle response is restored, and the chassis feels tight and composed again. Most importantly, this car is now set up for long-term ownership without chasing recurring issues.
This kind of work isn’t about shortcuts—it’s about doing the job once, doing it right, and preserving what makes the RS4 special.
Audi RS4 Service at Griffin Motorwerke
Griffin Motorwerke specializes in Audi, BMW, Porsche, and Volkswagen service, including engine-out repairs, major resealing work, and platform-specific upgrades. If your B7 RS4 is due for clutch work, timing service, carbon cleaning, or oil leak repair, our team can help you plan the right approach.
