3.2l - Lubrication - Engine Code(s): Cala (coupe) (as of 11.2007) Audi A5 I

OIL PAN, OIL PUMP AND COOLER ASSEMBLY OVERVIEW

Note. If large quantities of metal particles or abraded material are detected during engine repairs, it may be an indication for a damaged crankshaft or rod bearings. To prevent subsequent damage, the following work must be performed after the repair: Oil channels must be cleaned carefully; replace oil spray jets, oil cooler and oil filter. Oil capacities, specifications and viscosity classes see Fluid Capacity Chart. Oil injector jet for piston cooling (Scheme 1)

Scheme 1

1. Nut 9 Nm
2. Oil level thermal sensor -G266- Removing and installing «OIL LEVEL THERMAL SENSOR»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007__oil-level-thermal-sensor).
3. Seal Replace
4. Oil pan, lower Removing and installing «OIL PAN, LOWER»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007__oil-pan-lower).
5. Bolt 9 Nm
6. Lower oil baffle
7. Bolt Tightening specification and sequence (Scheme 4)
8. Oil pan, upper Removing and installing «OIL PAN, UPPER»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007__oil-pan-upper).
9. Alignment bushing 2 pieces
10. O-ring Insert into guide frame Replace
11. Bolt Insert with locking compound; 9 Nm
12. Upper oil baffle
13. Gasket Insert into guide frame Replace
14. Gasket Replace
15. Bolt 9 Nm
16. Oil cooler See note «OIL PAN, OIL PUMP AND COOLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007__oil-pan-oil-pump-and-cooler). Removing and installing «OIL COOLER»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007__oil-cooler). With oil cooler by-pass valve
17. Bolt 9 Nm
18. Driveshaft for oil pump
19. Spring
20. Sleeve 2 pieces
21. Bracket
22. Bolt 9 Nm
23. Chain sprocket for oil pump Can only be placed onto drive shaft in one position
24. Bolt Replace 30 Nm + an additional 90° turn To loosen, counter hold on sprocket with pin wrench 3212
25. O-ring Replace
26. Gasket Replace
27. O-ring Replace
28. Oil pump Do not disassemble Removing and installing «OIL PUMP»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007).
29. Bolt 20 Nm
30. Bolt Replace Tightening specification and sequence (Scheme 3)
31. Seal Replace
32. Oil drain plug 30 Nm

Scheme 2

Replace bolts for lower oil pan section -1-.

Tighten bolts in 2 stages in a diagonal sequence as follows

Connect electrical connector -2- on oil level thermal sensor -G266-.

Scheme 3

Tighten bolts -1 through 6- for upper oil pan section in 2 stages in a diagonal sequence as follows

Scheme 4

1. Bolt 13 Nm
2. Oil pressure switch -F22- Black insulation Removing and installing «OIL PRESSURE SWITCH»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007). 20 Nm
3. Seal Replace
4. Union nut 13 Nm
5. Bolt 9 Nm
6. Sleeve
7. Rubber grommet
8. Oil filter housing With filter by-pass valve With oil check valve Oil check valve cannot be replaced
9. O-ring Replace Inserting (Scheme 7)
10. Cap 25 Nm
11. Seal Replace Removing and installing (Scheme 6)
12. Oil filter element Removing and installing
13. Bolt 16 Nm
14. Gasket Replace

Scheme 5

Remove gasket -2- from cap -1- at pull tab -arrow A-.

Insert new sealing ring with semicircular profile in groove -arrow B- on the cap.

1. The pull tab -arrow A- must face up.

Scheme 6

Insert O-ring -2- in groove -arrow- on oil filter housing -1-.

Scheme 7

Tighten reduced oil pressure switch -F378- -1- to 20 Nm.

Scheme 8

1. O-ring Replace
2. Oil check valve For oil supply to right cylinder head 20 Nm
3. Gasket Replace
4. Cover with oil separator With connection for crankshaft housing ventilation Removing and installing «COVER WITH OIL SEPARATOR»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007) .
5. Bolt 9 Nm
6. Bolt 9 Nm
7. Bolt 3 Nm
8. Hose for crankcase ventilation To Intake manifold Removing and installing «CRANKCASE VENTILATION HOSES»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007) .
9. Crankcase ventilation hose To cylinder head covers Removing and installing «CRANKCASE VENTILATION HOSES»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007) .
10. O-rings Replace
11. Hose for crankcase ventilation To air guide pipe
12. Oil check valve For oil supply to left cylinder head 20 Nm
13. O-ring Replace

FASTENER TIGHTENING SPECIFICATIONS

LOWER OIL PAN BOLT TIGHTENING SEQUENCE AND SPECIFICATION

Replace bolts for lower oil pan section -1-.

Tighten bolts in 2 stages in a diagonal sequence as follows

Pre-tighten to 5 Nm.

Tighten an additional 90° turn.

UPPER OIL PAN BOLT TIGHTENING SEQUENCE AND SPECIFICATION

Tighten bolts -1 through 6- for upper oil pan section in 2 stages in a diagonal sequence as follows

Pre-tighten to 5 Nm.

Tighten to 16 Nm.

ENGINE OIL SPECIFICATIONS

For oil capacities, specifications and viscosity classes see Fluid Capacity Chart.

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

Remove oil pressure switch -F22- OIL PRESSURE SWITCH .

Connect oil pressure gauge V.A.G 1342 to oil pressure switch hole.

Install oil pressure switch -F22- in oil pressure gauge V.A.G 1342.

Start engine.

1. Oil pressure at idle: at least 2.5 bar pressure.
2. Oil pressure at 2000 RPM: at least 2.5 bar pressure.

ASSEMBLING

Install oil pressure switch -F22- OIL PRESSURE SWITCH .

ENGINE OIL, CHECKING LEVEL

=> 811

OIL COOLER

Special tools and workshop equipment required

1. Old oil collecting and extracting device V.A.G 1782

REMOVING

Proceed as follows

Remove bolt -1- and nut -3- and lock carrier left brace -2-.

Scheme 9

Drain coolant COOLING SYSTEM, DRAINING AND FILLING or, in countries with hot climates, remove after-run coolant pump -V51- AFTER-RUN COOLANT PUMP .

Remove coolant hose -1- from oil cooler.

Scheme 10

Place used oil collecting and extracting device V.A.G 1782 under engine.

Remove bolts -arrows- and oil cooler.

INSTALLING

1. Tightening specifications «OIL PAN, OIL PUMP AND COOLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007__oil-pan-oil-pump-and-cooler) .

Installation is in reverse order of removal, note the following

Note. Replace the gaskets and seals. Secure all hose connections with hose clamps appropriate for the model.

Install after-run coolant pump -V51- AFTER-RUN COOLANT PUMP .

Install lock carrier brace Description and Operation .

Engine oil level, checking ENGINE OIL, CHECKING LEVEL .

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING => Filling .

OIL LEVEL THERMAL SENSOR

Special tools and workshop equipment required

1. Old oil collecting and extracting device V.A.G 1782

Proceed as follows

Remove noise insulation by loosening fasteners -1- and -2-.

Scheme 11

Place used oil collecting and extracting device V.A.G 1782 below and drain the oil.

Disconnect electrical connector -3-.

Scheme 12

Remove nuts -1- and oil level thermal sensor -G266- -4-.

1. Tightening specifications «OIL PAN, OIL PUMP AND COOLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007__oil-pan-oil-pump-and-cooler) .

Installation is in reverse order of removal, note the following

Note. Replace the seal -2-.

Fill engine oil and check oil level ENGINE OIL, CHECKING LEVEL .

Install front noise insulation Description and Operation .

OIL PAN, LOWER

Special tools and workshop equipment required

1. Old oil collecting and extracting device V.A.G 1782
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Proceed as follows

Remove oil cooler OIL COOLER .

Place used oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.

Remove nuts -arrows- and stabilizer bar.

Scheme 13

On vehicles automatic transmission, remove bolt -arrow- for ATF lines.

Scheme 14

Note. Ignore -1 and 2-.

Disconnect electrical connector -2- on oil level thermal sensor -G266- and free up electrical wire.

Remove bolts -1- for lower section of oil pan.

Carefully loosen lower section of oil pan from bond without bending it.

1. Tightening specifications (Scheme 3)

Note. Replace sealing rings. Replace the lower section of the oil pan if the coating on it is damaged or if it is bent.

Remove sealant residue on lower and upper sections of oil pan, for example using a rotating plastic brush.

Scheme 15

Note. Make sure coating on the lower section of the oil pan is not damaged.

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

Cut tube nozzle at front marking (nozzle diameter approximately 1 mm).

Scheme 16

Apply sealant bead -arrow- to clean sealing surfaces of the lower section of the oil pan as shown in the illustration.

Scheme 17

1. Thickness of sealant bead: approximately 1.5 mm

Note. Install lower section of the oil pan within five minutes of applying the sealant.

Position lower section of oil pan and tighten bolts (Scheme 3)

The rest of installation is in reverse order of removal, note the following

On vehicles with automatic transmission, install the ATF lines Description and Operation or to Description and Operation .

Install stabilizer bar Removal and Installation .

Install oil cooler OIL COOLER .

Fill engine oil and check oil level ENGINE OIL, CHECKING LEVEL .

Remove lower section of oil pan OIL PAN, LOWER .

Remove bolts -arrows-.

Scheme 18

Remove oil pump forward from input shaft.

1. Tightening specifications «OIL PAN, OIL PUMP AND COOLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007__oil-pan-oil-pump-and-cooler) .

Installation is in reverse order of removal, note the following

Note. Replace O-rings.

Install oil pump onto drive shaft and fasten.

Install oil pan (lower part) OIL PAN, LOWER .

Fill engine oil and check the oil level ENGINE OIL, CHECKING LEVEL .

OIL PAN, UPPER

Special tools and workshop equipment required

1. Protective glasses
2. Hand drill with plastic brush attachment
3. Sealant

Proceed as follows

1. Secure engine on engine and transmission holder «ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-112007__engine-securing-to-engine-and-transmission) , or «ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-112007__engine-securing-to-engine-and-transmission) .

Remove timing chain lower cover LOWER TIMING CHAIN COVER .

Remove oil pump OIL PUMP .

Remove bolts -arrows- and remove oil baffle downward.

Scheme 19

Remove bolts -1 to 6- for upper section of the oil pan.

Press upper section of oil pan off cylinder block alignment pins.

1. Tightening specifications «OIL PAN, OIL PUMP AND COOLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007__oil-pan-oil-pump-and-cooler), (Scheme 4)

Note. Replace gaskets and O-rings.

Remove sealant residue on upper section of the oil pan and cylinder block, for example using a rotating plastic brush.

Scheme 20

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

Cut tube nozzle at the front marking (nozzle diameter approximately 1.5 mm).

Apply a sealant bead -arrow- to the clean sealing surface on the upper section of the oil pan as shown in the illustration.

Scheme 21

1. Completely fill the grooves on sealing surfaces with sealant.
2. The sealant bead must be 1.5 to 2.0 mm above sealing surface.

Note. Install the upper section of the oil pan within five minutes of applying the sealant.

Insert seal -1- and O-ring -2- in guide frame.

Scheme 22

Position upper section of oil pan and tighten bolts (Scheme 4)

The rest of installation is in reverse order of removal, note the following

Install oil pump OIL PUMP .

Install timing chain lower cover LOWER TIMING CHAIN COVER .

OIL FILTER HOUSING

Special tools and workshop equipment required

1. Old oil collecting and extracting device V.A.G 1782

Remove rear engine cover -top arrows-.

Scheme 23

Remove oil filter element.

Extract engine oil from oil filter housing using used oil collecting and extracting device V.A.G 1782.

Remove electrical connectors -1 through 4- from bracket and press to the side.

Scheme 24

Remove bolts -arrows-, free up bracket and remove it.

Note. Place a cloth under oil filter housing to catch escaping engine oil.

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

Scheme 25

Remove bolts -arrows-.

Scheme 26

Remove nut -1- and double bolt and then remove oil filter housing.

1. Tightening specifications «OIL FILTER HOUSING AND PRESSURE SWITCH ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace gaskets, seals and O-rings.

Install oil filter element

Fill engine oil and check the oil level ENGINE OIL, CHECKING LEVEL .

Remove rear engine cover -top arrows-.

Note. Place a cloth under oil filter housing to catch escaping engine oil.

Disconnect electrical connector -arrow- on oil pressure switch -F22-.

Remove oil pressure switch -F22-.

1. Tightening specifications «OIL FILTER HOUSING AND PRESSURE SWITCH ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace sealing ring. To prevent coolant loss, insert new oil pressure switch -F22- in connecting pieces immediately.

Engine oil level, checking ENGINE OIL, CHECKING LEVEL .

Remove rear engine cover -top arrows-.

Disconnect electrical connector -2-.

Remove reduced oil pressure switch -F378- -1-.

1. Tightening specifications (Scheme 8)

Installation is in reverse order of removal, note the following

Note. Replace sealing ring.

OIL PRESSURE REGULATION VALVE

Special tools and workshop equipment required

1. Old oil collecting and extracting device V.A.G 1782

Proceed as follows

Without After-Run Coolant Pump -V51

Remove noise insulation by loosening fasteners -1- and -2-.

Remove bolt -1- and nut -3- and lock carrier left brace -2-.

Place used oil collecting and extracting device V.A.G 1782 under engine.

Remove bolts -arrows- and lay aside oil cooler with coolant hoses -1- and -2- connected.

With After-Run Coolant Pump -V51

Remove after-run coolant pump -V51- AFTER-RUN COOLANT PUMP , and oil cooler OIL COOLER .

Continuation for All

Disconnect electrical connector -1-.

Scheme 27

Remove bolt -3- and oil pressure regulation switch -N428- -4-.

1. Tightening specifications (Scheme 29)

Installation is in reverse order of removal, note the following

Note. Replace O-ring -2-.

Install oil cooler OIL COOLER .

Note. During installation, all cable ties must be reinstalled at the same location.

Remove upper section of intake manifold Removal and Installation .

Remove crankcase ventilation hoses -arrows- from cylinder head covers.

Scheme 28

Note. The crankcase ventilation hoses cannot be removed from the cylinder head covers without being destroyed. Crankcase ventilation hoses must be replaced after being removed.

Free up crankcase ventilation hoses.

Remove bolt -1- and connections for crankcase ventilation hoses.

1. Tightening specifications «OIL CHECK VALVES AND SEPARATOR ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace seals and O-rings.

Install upper section of intake manifold Removal and Installation .

Remove crankcase ventilation hoses CRANKCASE VENTILATION HOSES .

Remove left lower section of intake manifold Removal and Installation .

Remove upper coolant pipe UPPER COOLANT PIPE .

Remove bolts -arrows-.

Scheme 29

Remove high pressure line bracket and oil separator -1-.

1. Tightening specifications «OIL CHECK VALVES AND SEPARATOR ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace the gasket.

Install upper coolant pipe UPPER COOLANT PIPE .

Install left lower section of intake manifold Removal and Installation .

Install crankcase ventilation hoses CRANKCASE VENTILATION HOSES .

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 30

Scheme 31

1. Oil pressure gauge V.A.G 1342
2. Old oil collecting and extracting device V.A.G 1782

See also:
• COOLING SYSTEM, DRAINING AND FILLING
• AFTER-RUN COOLANT PUMP
• Description and Operation
• Description and Operation
• Description and Operation
• Removal and Installation
• ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER
• LOWER TIMING CHAIN COVER
• Removal and Installation
• UPPER COOLANT PIPE
• OIL LEVEL THERMAL SENSOR
• OIL PAN, LOWER
• OIL PAN, UPPER
• OIL PAN, OIL PUMP AND COOLER ASSEMBLY OVERVIEW
• OIL COOLER
• OIL PUMP
• ENGINE OIL, CHECKING LEVEL