2.0L - Lubrication - Engine Code(s): Bpy: Other Audi A3 8P facelift

OIL PUMP AND OIL PAN

Note. If large quantities of metal particles or other deposits (caused, for example, by partial seizure of the crankshaft or connecting rod damage) are found in the engine oil, the oil passages must be cleaned thoroughly and the oil cooler replaced in order to prevent further damage from occurring.

Oil pressure, checking, refer to OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING .

Viscosity classes and oil specifications

Oil system capacity

CHAIN TENSIONER, TENSIONING

Pretension the piston by hand -arrow-.

Scheme 40

Push the chain rail in direction of -arrow- and secure it with an Allen wrench -1-, wrench diameter 3 mm.

Scheme 41

OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING

Special tools and workshop equipment required

1. Oil Pressure Gauge V.A.G 1342
2. Voltage Tester V.A.G 1527 B
3. Connector Test Kit V.A.G 1594 C

Test Prerequisites

1. Engine oil level OK, checking
2. The oil pressure warning lamp must light up for approximately 3 seconds when the ignition is switched on.
3. On vehicles with auto-check-system, the indicator "OK" must light up (check symbol).
4. Engine oil temperature at least 80 °C (176 °F) (radiator fan must start up once).

Test Sequence

1. For the correct tightening specifications, refer to «OIL FILTER BRACKET OVERVIEW»(ref-496104-S22478605892012082100000)

Remove oil pressure switch -F1- -A- and screw it into oil pressure gauge.

Scheme 42

Thread oil pressure gauge into oil filter bracket in place of oil pressure switch.

Connect the tester brown wire to Ground (GND).

Connect V.A.G 1527 B using adapter cables from V.A.G 1594 C to battery B positive and oil pressure switch -B-. LED must not light up.

If LED lights up, replace 1.4 bar oil pressure switch.

If the LED does not light up

Start engine and increase engine speed: LED must light up at 1.2 to 1.6 bar positive pressure, otherwise replace oil pressure switch. Increase engine speed further. At 2000 RPM and an oil temperature of 80 °C (176 °F), the oil pressure should be between 2.7 bar and 4.5 bar.

OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING (1-PIN OIL PRESSURE SWITCH)

Note. 1-pin and 2-pin oil pressure switches are installed. Check which oil pressure switch is installed. Check the oil pressure and oil pressure switch (2-pin oil pressure switch). Refer to OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING (2-PIN OIL PRESSURE SWITCH) .

Special tools and workshop equipment required

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

1. Engine oil level OK
2. Engine oil temperature at least 80 °C (176 °F) (radiator fan must start up once).

Remove the oil pressure switch -F1-. Refer to Oil Pressure Switch -F1 .

Install the V.A.G 1342 in the hole for the oil pressure switch in the oil filter bracket.

Connect the tester brown wire to Ground (GND).

Connect V.A.G 1527 B using adapter cables from V.A.G 1594C to B+ and oil pressure switch. LED must not light up.

If LED lights up, replace 1.4 bar oil pressure switch.

If the LED does not light up

Start engine and increase engine speed: The LED must illuminate at 1.2 to 1.6 bar. Replace the oil pressure switch if it does not.

Increase engine speed further. At 2000 RPM and an oil temperature of 80 °C (176 °F), the oil pressure must be between 2.7 and 4.5 bar.

At higher engine speeds oil pressure must not exceed 7.0 bar

OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING (2-PIN OIL PRESSURE SWITCH)

Note. 1-pin and 2-pin oil pressure switches are installed. Check which oil pressure switch is installed. Check the oil pressure and oil pressure switch (1-pin oil pressure switch). Refer to OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING (1-PIN OIL PRESSURE SWITCH) .

Special tools and workshop equipment required

1. Oil Pressure Gauge V.A.G 1342
2. Test Adapter F/ VAS 5051 DSO (2 Pin) VAS 5256
3. Hand-Held Multimeter V.A.G 1526D

Procedure

1. Engine oil level OK
2. Engine oil temperature at least 80 °C (176 °F) (radiator fan must start up once).

Remove the oil pressure switch -F1-. Refer to Oil Pressure Switch -F1 and screw it into the V.A.G 1342.

Scheme 43

Screw V.A.G 1342 into the oil filter bracket in place of the oil pressure switch.

Attach the VAS 5256 to the oil pressure switch.

Connect the V.A.G 1526D to the VAS 5256 and set it for the continuity test.

1. The oil pressure switch must be open at less than 1.2 bar.

Start engine and increase engine speed: The oil pressure switch must close at 1.2 to 1.6 bar. Replace the oil pressure switch if it does not.

Increase engine speed further. At 2000 RPM and an oil temperature of 80 °C (176 °F), the oil pressure must be between 2.7 and 4.5 bar.

At higher engine speeds oil pressure must not exceed 7.0 bar

OIL PRESSURE, CHECKING

Special tools and workshop equipment required

1. Oil Pressure Gauge V.A.G 1342

Procedure

1. Oil level OK
2. Engine oil temperature approximately 80 °C (176 °F).

Remove oil pressure switch. Refer to Oil Pressure Switch -F1 .

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

Install the V.A.G 1342 in the hole for the oil pressure switch in the oil filter bracket.

Start the engine.

1. Oil pressure at idle at least 1.2 bar.
2. Oil pressure at 2000 RPM at least 2.7 bar.

Install oil pressure switch. Refer to Oil Pressure Switch -F1 .

Oil Level Thermal Sensor -G266

Removing

Drain engine oil.

Disconnect the connector -5-.

Scheme 44

Remove the three bolts -1- and the cover -2-.

Remove the oil level thermal sensor -3- from the oil pan and remove it with the seal -4-.

Installing

1. Tightening specifications, refer to «OIL PAN OVERVIEW»(ref-496104-S40467761202012082100000) .

Install in reverse order of removal. Note the following

Note. Replace the seal.

Fill the engine oil and check the oil level.

OIL PAN

Special tools and workshop equipment required

1. Hex Ball Socket T10058
2. Hand drill with plastic brush attachment
3. Protective eyewear

Removing

Remove the engine cover and air filter. Refer to Removal and Installation .

Remove noise insulation. Refer to Removal and Installation .

Remove right noise insulation fasteners -1 to 3-.

Scheme 45

Disconnect air guide pipe -arrow- from charge air cooler.

Scheme 46

Unfasten air duct from turbocharger -arrows-.

Scheme 47

Remove bolts -arrows- and remove air guide pipe.

Scheme 48

Remove the air duct -1- for charge air cooler.

Scheme 49

Disconnect connector from charge air pressure sensor -G31-. Refer to Description and Operation .

Remove air duct.

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

Scheme 50

Remove oil return pipe -arrows- from turbocharger.

Drain engine oil.

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

Remove the bolts -1 to 20- in a diagonal sequence.

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

Installing

1. For the correct tightening specifications, refer to «OIL PAN OVERVIEW»(ref-496104-S40467761202012082100000)

Note. Note the expiration date of the silicone sealant. The oil pan must be installed within 5 minutes after application of silicone sealant.

Remove sealant residue from cylinder block with a flat scraper.

Remove residual sealant on the oil pan for example with a rotating plastic brush.

Scheme 51

Clean sealing surfaces, must be free of oil and grease.

Cut the tube nozzle at the front marking (nozzle diameter: approximately 0.12 in).

Scheme 52

Apply silicone sealing compound bead as illustrated to clean sealing surface of oil pan.

Scheme 53

1. Thickness of sealant bead: 2 to 3 mm

Note. The oil pan must be installed within 5 minutes after application of silicon sealant. The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube. Apply a bead of sealant at the rear area of the sealing flange very carefully -arrows- in the illustration.

Immediately position oil pan in place and tighten bolts, tightening sequence. see scheme 4

Note. When installing the oil pan to a removed engine, make sure that the oil pan is positioned flush with the cylinder block on the flywheel side. 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.

Further assembly is performed in the reverse order of removal, thereby observing the following

Air guide pipes with connector, installing. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS .

BALANCE SHAFT MODULE WITH OIL PUMP

Special tools and workshop equipment required

1. Connecting Pin T10027 A

Removing

Remove oil pan. Refer to OIL PAN .

Note. Turning over the engine is performed at the center bolt of the crankshaft.

Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must align with -arrow- on toothed belt guard.

Scheme 54

Pull off chain guard. Disengage locking lugs through openings -arrows- if necessary using a small screwdriver.

Scheme 55

Loosen the bolt from oil pump chain sprocket. Counter-hold at the center bolt for vibration damper.

Scheme 56

Release tension on chain rail using a screwdriver -arrow- and secure it using an Allen wrench -1-, across flats 3 mm.

Scheme 57

Remove chain sprocket of oil pump and disengage chain on differential shaft drive.

Scheme 58

Remove the bolts -1 and 2- and the oil baffle.

Scheme 59

Remove bolts -arrows- from balance shaft assembly from outside to inside and remove it.

Installing

1. For the correct tightening specifications, refer to «BALANCE SHAFT MODULE WITH OIL PUMP OVERVIEW»(ref-496104-S11219126242012082100000)
2. Chain tensioner tensioned, refer to «CHAIN TENSIONER, TENSIONING»(ref-496104-S36634200372012082100000)

Replace all balance shaft assembly bolts.

Replace balance shaft assembly bolt gasket BALANCE SHAFT MODULE WITH OIL PUMP OVERVIEW .

Place intermediate plate as shown on to alignment bushings of differential shaft gear -arrows-.

Scheme 60

Install balance shaft assembly with oil pump and intermediate plate. Tighten bolts -arrows- from inside toward outside.

Note. Note different length of bolts see scheme 8 Observe tightening sequence see scheme 9 Pay attention to alignment sleeves.

Install oil baffle and insert pins in balance shaft module -arrows-.

Note. Turning over the engine is performed at the center bolt of the crankshaft.

Bring the engine to TDC at cylinder 1 by turning the crankshaft in the direction of engine rotation at the crankshaft toothed belt sprocket center bolt. The markings on the camshaft sprocket and the crankshaft must be positioned at cylinder 1 TDC -arrows-.

Set marking on chain sprocket of differential shaft -arrow- opposite alignment bore. Secure chain sprocket in this position using the T10027 A. Place chain on to differential shaft chain sprocket.

Scheme 61

Install oil pump chain sprocket with new bolt and tighten bolt by hand.

Note. Oil pump chain sprocket fits only in one position. To install, only the oil pump must be turned.

Remove the T10027 A and Allen wrench -1-. Secure chain sprocket of the oil pump. Counter-hold at the center bolt for vibration damper.

Assemble in reverse order of disassembly.

Install oil pan. Refer to OIL PAN .

OIL COOLER

Special tools and workshop equipment required

1. Drip Tray VAS 6208
2. Hose Clip Pliers VAS 5024 A

Removing

Open cap of coolant expansion tank.

Remove the engine cover and air filter. Refer to Removal and Installation .

Remove noise insulation. Refer to Removal and Installation .

Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Remove the intake manifold and fuel rail. Refer to Removal and Installation .

Remove bracket for cable connector -arrows- from coolant pipe.

Scheme 62

Disconnect coolant hose -1-.

Scheme 63

Remove the bolt -2-.

Disconnect coolant hoses -arrows- from coolant pipe.

Scheme 64

Remove bolt -1- and remove coolant pipe.

Remove the oil cooler -arrows-.

Scheme 65

Installing

Install in reverse order of removal. Note the following

1. For the correct tightening specifications, refer to «OIL FILTER BRACKET OVERVIEW»(ref-496104-S22478605892012082100000)

Note. Always replace gaskets and seals.

Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

OIL FILTER BRACKET

Special tools and workshop equipment required

1. Drip Tray VAS 6208
2. Hose Clip Pliers VAS 5024 A
3. Locking Pin T10060A

Removing

Open cap of coolant expansion tank.

Removing

Remove the engine cover and air filter. Refer to Removal and Installation .

Remove noise insulation. Refer to Removal and Installation .

Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Pivot the ribbed belt tensioner in direction of -arrow- to relieve tension on ribbed belt.

Scheme 66

Secure tensioning element using the T10060A.

Scheme 67

Remove ribbed belt.

Remove ribbed belt tensioner -arrows-.

Scheme 68

Remove the generator. Refer to REMOVAL AND INSTALLATION

Remove the intake manifold and fuel rail. Refer to Removal and Installation .

Remove bracket for cable connector -arrows- from coolant pipe.

Disconnect coolant hose -1-.

Remove the bolt -2-.

Disconnect coolant hoses -arrows- from coolant pipe.

Remove bolt -1- and remove coolant pipe.

Remove the oil cooler -arrows-.

Disconnect crankcase ventilation pipe -1-.

Scheme 69

Remove ground (GND) cable -2- for oil pressure switch.

Remove bolts -arrows- and remove oil filter bracket.

Installing

Install in reverse order of removal. Note the following

1. For the correct tightening specifications, refer to «OIL FILTER BRACKET OVERVIEW»(ref-496104-S22478605892012082100000)

Note. Always replace gaskets and seals.

Insert baffle plate OIL FILTER BRACKET OVERVIEW .

Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Oil Pressure Switch -F1

Special tools and workshop equipment required

1. Assembly Tool T10118
2. Socket 24 mm and Jointed Extension T40175

Removing

Remove the noise insulation. Refer to Removal and Installation .

Remove left charge air hose -1 and 2-.

Remove the connector -1- from the bracket and disconnect the connector -arrow- from the oil pressure switch using the T10118.

Scheme 70

Remove the oil pressure switch with the T40175.

Scheme 71

Installing

1. Tightening specifications, refer to «OIL FILTER BRACKET OVERVIEW»(ref-496104-S22478605892012082100000) .

Install in reverse order of removal. Note the following

Note. In the case of a 1-pin oil pressure switch, check whether the ground (GND) wire is connected. The hose supports, air guide pipes and hoses must be free of oil and grease before installing.

Scheme 72

Special tools and workshop equipment required

1. Oil Pressure Gauge V.A.G 1342
2. Voltage Tester V.A.G 1527 B
3. Connector Test Kit V.A.G 1594 A

Scheme 73

Special tools and workshop equipment required

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

Special tools and workshop equipment required

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

1. Oil Drain Adapter T40057
2. Test Adapter F/ VAS 5051 DSO (2 Pin) VAS 5256
3. Hand-Held Multimeter V.A.G 1526D
4. Hex Ball Socket T10058
5. Connecting Pin T10027 A
6. Locking Pin T10060A
7. Drip Tray VAS 6208
8. Hose Clip Pliers VAS 5024 A
9. Assembly Tool T10118
10. Socket 24 mm and Jointed Extension T40175