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3.2l - Lubrication - Engine Code(s): Bub & Cbra Audi A3 8P рестайлинг

Lubrication System 27 illustrations ~1824 words

OIL PUMP AND OIL PAN

Note. If a large amount of metal shavings or particles were found when performing engine repairs, these could indicated crankshaft or rod bearings are damaged. To prevent further damage, the following steps must be carried out after the repair: Oil channels must be cleaned carefully; replace oil spray jets, oil cooler and oil filter. For engine oil capacities and specifications, refer to the Owner's Manual.

CAUTIONDanger of catalytic converter damage. Oil level must not exceed "max" marking.

ENGINE OIL

For engine oil capacities and specifications, refer to the Owner's Manual.

Scheme 1

Scheme 1: OIL PUMP AND OIL PAN ASSEMBLY OVERVIEW
Scheme 1: OIL PUMP AND OIL PAN ASSEMBLY OVERVIEW
  1. 5 Nm Fastened to intake manifold
  2. Oil Dipstick
  3. Guide Tube for Oil Dipstick
  4. Cylinder Block
  5. Oil Return Valve Removal and installation (Scheme 3)Note installation position
  6. 8 Nm
  7. Oil Pump Drive Cover
  8. O-ring Replace Oil to install
  9. Oil Pump Drive
  10. Intermediate Shaft
  11. Thrust Washer
  12. 10 Nm Insert with locking compound.
  13. Oil Spray Jet for Piston Cooling For crankshaft bearing 2 to 7 Opening pressure 2.0 bar pressure Removal and installation (Scheme 4)
  14. Oil Pump Driveshaft
  15. Oil Pump Disassembling and assembling, refer to «OIL PUMP ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/lubrication-system/#32l-lubrication-engine-codes-bub-cbra) Coat the oil pressure tube on the cylinder block and oil pump housing with sealing paste.
  16. 23 Nm
  17. Oil Drain Plug - 30 Nm
  18. Oil Pan Removal and installation, refer to «OIL PAN»(/audi/a3/8p-2004-2008/remont/lubrication-system/#32l-lubrication-engine-codes-bub-cbra__oil-pan) Tightening specifications and tightening sequence (Scheme 2)
  19. Oil Level Thermal Sensor -G266- Removal and installation (Scheme 5)
  20. Bolt Tightening specifications and tightening sequence (Scheme 2)
  21. Oil Filter Housing Component overview, refer to «OIL COOLER AND OIL FILTER HOUSING ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/lubrication-system/#32l-lubrication-engine-codes-bub-cbra) Removal and installation, refer to «OIL FILTER HOUSING»(/audi/a3/8p-2004-2008/remont/lubrication-system/#32l-lubrication-engine-codes-bub-cbra__oil-filter-housing)

Scheme 2

Scheme 2
Scheme 2

Tighten bolts in 3 stages as follows

Pre-tighten the bolts connect the oil pan to the cylinder block in a diagonal sequence to 5 Nm.

Tighten oil pan to transmission connection -arrows- bolts.

Tighten oil pan to cylinder block connection bolts diagonally to 12 Nm.

Note. Ignore -1-.

Scheme 3

Scheme 3
Scheme 3

To remove, turn bolt M8x1.5 approximately 4 turns in valve -arrow- and remove valve.

To install, coat O-ring with oil and press valve by hand into oil channel.

Scheme 4

Scheme 4
Scheme 4

Note. The oil spray jets are installed into crankshaft bearings 2 to 7.

To remove oil spray jets, press out with a drift dia. 4 mm toward crankshaft bearing.

To install oil spray jets, press in by hand using a drift dia. 6 mm -arrow-.

Scheme 5

Scheme 5
Scheme 5
  1. Bolt - 10 Nm; self-locking, replace
  2. Sealing ring; replace
  3. Electrical harness connector
  4. Oil Level Thermal Sensor -G266

Scheme 6

Scheme 6: OIL PUMP ASSEMBLY OVERVIEW
Scheme 6: OIL PUMP ASSEMBLY OVERVIEW
  1. Oil Pump Driveshaft
  2. Oil Pump Housing
  3. 23 Nm
  4. Gears Checking backlash (Scheme 7)Checking axial play (Scheme 8)
  5. Oil Pump Cover With check-valve Check-valve opening pressure: 5.3 to 5.7 bar positive pressure Clean strainer if soiled
  6. 8 Nm Insert with locking compound.
  7. Oil Pressure Line Coat at cylinder block and at oil pump housing with sealing paste.
  8. 10 Nm
  9. Seal Replace if damaged

Scheme 7

Scheme 7
Scheme 7

Use a feeler gauge to measure.

  1. Backlash wear limit: 0.20 mm

Scheme 8

Scheme 8
Scheme 8

Use feeler gauge and straight edge to measure.

  1. Axial clearance wear limit: 0.10 mm.

Scheme 9

Scheme 9: OIL COOLER AND OIL FILTER HOUSING ASSEMBLY OVERVIEW
Scheme 9: OIL COOLER AND OIL FILTER HOUSING ASSEMBLY OVERVIEW
  1. Cap Tighten to 25 Nm.
  2. O-ring Replace
  3. Oil Filter Element Removal and installation
  4. Oil Filter Housing With oil check valve
  5. 23 Nm
  6. Locking Bolt - 15 Nm
  7. Seal Cut and replace if leaking
  8. Seal Cut and replace if leaking
  9. Oil Pressure Switch -F1- Black insulation Operating pressure 1.4 bar Checking, refer to «OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING»(/audi/a3/8p-2004-2008/remont/lubrication-system/#32l-lubrication-engine-codes-bub-cbra__oil-pressure-and-oil-pressure-switch) Removal and installation, refer to «OIL PRESSURE SWITCH»(/audi/a3/8p-2004-2008/remont/lubrication-system/#32l-lubrication-engine-codes-bub-cbra__oil-pressure-switch) Tighten to 25 Nm.
  10. Seals Replace
  11. Cap Tighten to 25 Nm.
  12. Seal Replace Oil to install
  13. Oil Cooler Ensure clearance to surrounding parts Coolant hose connection diagram, refer to «COOLANT HOSE CONNECTION DIAGRAM»(/audi/a3/8p-2004-2008/remont/cooling-fan/#32l-cooling-system-engine-codes-bub-cbra) Observe note when repairing engine «OIL PUMP AND OIL PAN»(/audi/a3/8p-2004-2008/remont/lubrication-system/#32l-lubrication-engine-codes-bub-cbra__oil-pump-and-oil-pan)
  14. Seal Installed location (Scheme 10)Oil to install clamp tightly to oil cooler with plastic insert -15
  15. Plastic Insert Insert in oil cooler together with seal -14- Installed location (Scheme 10)

Scheme 10

Scheme 10
Scheme 10

First insert oil-coated seal in oil cooler.

Insert plastic insert in oil cooler.

  1. Side without ribs on plastic insert must align with tab -arrow- on oil cooler.

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Guide tube for Oil Dipstick5
Oil Cooler Cap25
Oil Drain Plug30
Oil Filter Cap25
Oil Filter Housing
Locking Bolt15 2
23 2
Oil Level Thermal Sensor8
Oil Pressure Line8
Oil Pressure Switch25
Oil Pump23
Oil Pump Drive Cover8
Oil Pump Housing
10 1
23 1
Thrust Washer10
1 For bolt tightening clarification, refer to OIL PUMP ASSEMBLY OVERVIEW and see items -3 and 8- 2 For bolt tightening clarification, refer to OIL COOLER AND OIL FILTER HOUSING ASSEMBLY OVERVIEW and see items -5 and 6

Oil Pan - Tightening Specifications and Tightening Sequence

Tighten bolts in 3 stages as follows

Pre-tighten the bolts connect the oil pan to the cylinder block in a diagonal sequence to 5 Nm.

Tighten oil pan to transmission connection -arrows- bolts.

Tighten oil pan to cylinder block connection bolts diagonally to 12 Nm.

Note. Ignore -1-.

OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING

Special tools and workshop equipment required

  1. Oil Pressure Gauge V.A.G 1342
  2. Adapter V.A.G 1342/14
  3. Voltage Tester V.A.G 1527B
  4. Connector Test Set V.A.G 1594C

Procedure

  1. Oil level OK
  2. Engine oil temperature approximately 80 °C / 176 °F.
  3. "OK" display must light up in Driver Information Display (DIS).

Remove oil pressure switch. Refer to OIL PRESSURE SWITCH .

Connect V.A.G 1342 with V.A.G 1342/14 to oil pressure switch hole.

Scheme 11

Scheme 11
Scheme 11

Install the oil pressure switch in the V.A.G 1342.

Install oil dipstick guide tube and insert dipstick.

Install A/C compressor. Refer to Removal and Installation .

Install ribbed belt. Refer to RIBBED BELT .

Oil Pressure Switch, Checking

Connect the oil pressure gauge brown wire to Ground "negative".

Connect V.A.G 1527B using adapter cables from V.A.G 1594C to oil pressure switch and battery ("positive").

  1. LED must not light up.

If the LED lights up with the engine at standstill, replace oil pressure switch.

Start engine.

Note. Because the switch point for oil pressure switch can be exceeded upon starting, watch oil pressure gauge

  1. The LED must illuminate at 1.2 to 1.6 bar.

If the LED does not light up, replace oil pressure switch.

Oil Pressure, Checking

Start engine.

  1. Oil pressure at 1500 RPM: min. 1.7 bar.
  2. Oil pressure at 2000 RPM: min. 2.5 bar.

Assembling

Install oil pressure switch. Refer to OIL PRESSURE SWITCH .

OIL LEVEL, CHECKING

Procedure

  1. Engine oil temperature min. 60 °C / 140 °F.
  2. Vehicle in level position.
  3. After stopping engine, wait a few minutes to allow oil to flow back into oil pan.

Pull out oil dipstick, wipe off with a clean cloth and re-insert dipstick again up to stop.

Withdraw dipstick again and check the oil level.

Range of markings on dipstick

Scheme 12

Scheme 12
Scheme 12

a

Oil must not be added.

b

Oil may be topped off. After topping off, oil may be in range -a-.

c

Oil must be added. After topping off, it is sufficient if oil level is somewhere in range -b- (shaded area).

Note. Oil level must not exceed max. marking -arrow 1- and must not fall short of min. marking -arrow 2-.

OIL PAN

Special tools and workshop equipment required

  1. Used Oil Collection and Extraction Device V.A.G 1782
  2. Hand drill with plastic brush attachment
  3. Protective eyewear

Removing

Disconnect secondary air hose at position indicated by -arrow-.

Scheme 13

Scheme 13
Scheme 13

Remove center noise insulation fasteners -1 to 3-.

Scheme 14

Scheme 14
Scheme 14

Remove right noise insulation fasteners -1 to 3-.

Scheme 15

Scheme 15
Scheme 15

Drain engine oil.

Free up coolant hose at bottom on fan shroud.

Scheme 16

Scheme 16
Scheme 16

Disconnect electrical connector -3- at secondary air injection (AIR) pump motor -V101- and free up electrical wiring.

On vehicles with DSG transmission, remove coolant pipe bracket -2- to transmission oil cooler.

Remove bolts -1-.

Loosen bolt -4- and remove Secondary Air Injection (AIR) pump with bracket.

Disconnect electrical connector -1- at oil level thermal sensor -G266-.

Remove the bolts for oil pan/transmission -arrows-.

Loosen oil pan bolts -2- diagonally and remove.

Remove the oil pan, and if necessary loosen by applying light strikes with a rubber hammer.

Installing

  1. Tightening specifications, refer to «OIL PUMP AND OIL PAN ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/lubrication-system/#32l-lubrication-engine-codes-bub-cbra), (Scheme 2).

Installation is in reverse order of removal, note the following

Carefully remove sealant residue on cylinder block.

Scheme 17

Scheme 17
Scheme 17
WARNINGRisk of eye injury. Wear safety glasses.

Remove sealant residue on oil pan, for example with a rotating plastic brush.

Clean sealing surfaces so they are completely free of any oil or grease.

Cut tube nozzle at front marking (nozzle dia. approximately 2 mm).

Scheme 18

Scheme 18
Scheme 18

Apply sealant -arrow- to clean oil pan sealing surface, as shown in illustration.

Scheme 19

Scheme 19
Scheme 19
  1. Thickness of sealant bead: 2 mm.
CAUTIONRisk of plugging oil pump strainer with excess sealant. Do not apply sealant bead thicker than indicated.

Note. Apply sealant bead especially carefully in lower timing chain cover area. The oil pan must be installed within 5 minutes of being applied with sealant.

Tighten oil pan -2-. (Scheme 2)

Connect Oil Level Thermal Sensor -G266- electrical connectors -1-.

CAUTIONRisk of leaking at oil pan. After installing oil pan, allow sealant to dry for approximately 30 minutes. Only after then may the engine oil be replenished.

Add engine oil and check oil level. Refer to OIL LEVEL, CHECKING .

OIL FILTER HOUSING

Special tools and workshop equipment required

  1. Hose Clamps Up to 25 mm Dia. 3094
  2. Assembly Tool T10118

Removing

WARNINGRisk of scalding due to hot steam and hot coolant. When the engine is warm the cooling system is under pressure. Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

Open cap of coolant expansion tank.

Disconnect secondary air hose at position indicated by -arrow-.

Remove center noise insulation fasteners -1 to 3-.

Free up coolant hose at bottom on fan shroud.

Disconnect electrical connector -3- at secondary air injection (AIR) pump motor -V101- and free up electrical wiring.

On vehicles with DSG transmission, remove coolant pipe bracket -2- to transmission oil cooler.

Remove bolts -1-.

Loosen bolt -4- and remove Secondary Air Injection (AIR) pump with bracket.

Connect the coolant hoses -2- and -3- with 3094.

Scheme 20

Scheme 20
Scheme 20

Disconnect electrical connector -1- at oil pressure switch with T10118.

Disconnect coolant hoses -2- and -3- at oil filter bracket.

Remove bolts -arrows- and remove oil filter bracket.

Installing

  1. Tightening specifications, refer to «OIL COOLER AND OIL FILTER HOUSING ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/lubrication-system/#32l-lubrication-engine-codes-bub-cbra) .

Installation is in reverse order of removal, note the following

Note. Replace gaskets.

OIL PRESSURE SWITCH

Special tools and workshop equipment required

  1. Assembly Tool T10118

Removing

Remove ribbed belt. Refer to RIBBED BELT .

Remove oil dipstick.

Remove bolt -3-, remove oil dipstick guide tube -2- and lay aside.

Scheme 21

Scheme 21
Scheme 21

Note. Ignore items -1 and 4-.

Remove center noise insulation fasteners -1 to 3-.

Disconnect electrical harness connector -1- for A/C clutch on A/C compressor and free up electrical wire.

Scheme 22

Scheme 22
Scheme 22
WARNINGRisk of injury from refrigerant. The air conditioning refrigerant circuit must not be opened.

Remove bolts -arrows-.

Secure A/C compressor with refrigerant hoses attached to front of noise insulation frame.

Disconnect electrical connector -arrow- on oil pressure switch -F1- with T10118.

Scheme 23

Scheme 23
Scheme 23

Remove oil pressure switch -F1-.

Installing

  1. Tightening specifications, refer to «OIL COOLER AND OIL FILTER HOUSING ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/lubrication-system/#32l-lubrication-engine-codes-bub-cbra) .

Installation is in reverse order of removal, note the following

Install A/C compressor. Refer to Removal and Installation .

Install ribbed belt. Refer to RIBBED BELT .

Scheme 24

Scheme 24: SPECIAL TOOLS
Scheme 24: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Oil Pressure Gauge V.A.G 1342
  2. Adapter V.A.G 1342/14
  3. Voltage Tester V.A.G 1527B
  4. Connector Test Set V.A.G 1594C

Special tools and workshop equipment required

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27
  1. Used Oil Collection and Extraction Device V.A.G 1782
  2. Hose Clamps Up to 25 mm Dia. 3094
  3. Assembly Tool T10118

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