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2.0l - Lubrication - Engine Code(s): Bpy (roadster) Audi TT 8J

Lubrication System 49 illustrations ~2749 words

OIL FILTER HOUSING, DRAINING

Special tools and workshop equipment required

  1. Oil Drain Adapter T40057

Note. When screwing in the T40057, a valve in the oil filter housing is opened. If the T40057 is unscrewed, the valve closes again.

Unscrew dust cap from the oil filter housing -arrow-.

Scheme 76

Scheme 76
Scheme 76

Hold the hose of the T40057 in a catch pan and screw the T40057 into the oil filter housing.

Scheme 77

Scheme 77
Scheme 77

Let engine oil drain.

OIL PAN OVERVIEW

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, refer to Fluid Capacity Tables.

Oil system capacity, refer to Fluid Capacity Tables.

Balance shaft module, oil pump, refer to BALANCE SHAFT MODULE WITH OIL PUMP OVERVIEW

Oil filter bracket, refer to OIL FILTER BRACKET OVERVIEW

Scheme 78

Scheme 78: OIL PAN OVERVIEW
Scheme 78: OIL PAN OVERVIEW
  1. Bolt Tightening sequence (Scheme 80)
  2. Oil Dipstick Oil level must not be above the max. mark!
  3. Guide Tube for Oil Dipstick
  4. Guide Tube
  5. Intermediate Plate
  6. Balance Shaft Module with Oil Pump With pressure relief valve 12 bar Pay attention to alignment sleeves, refer to «BALANCE SHAFT MODULE WITH OIL PUMP OVERVIEW»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__balance-shaft-module-with-oil-pump) Balance shaft module with oil pump, assembly overview, refer to «BALANCE SHAFT MODULE WITH OIL PUMP OVERVIEW»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__balance-shaft-module-with-oil-pump) Removing and installing, refer to «BALANCE SHAFT MODULE WITH OIL PUMP»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__balance-shaft-module-with-oil-pump)
  7. Bolt Replace Note different length of bolts (Scheme 82)Tightening sequence (Scheme 83)
  8. Bolt Tightening sequence (Scheme 79)
  9. Oil Pan Clean sealing surface before installing Removing and installing, refer to «OIL PAN»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__oil-pan)
  10. Bolt Tightening sequence (Scheme 79)
  11. Seal Rolled onto OIL PAN OVERVIEW.
  12. Oil Drain Plug Replace 30 Nm With permanent sealing ring
  13. Chain Sprocket
  14. Bolt 10 Nm
  15. Protective Cap
  16. Oil Level Thermal Sensor -G266
  17. Seal Replace Oil before assembling
  18. Bolt Replace 20 Nm plus an additional 90° turn
  19. Chain Guard
  20. Chain
  21. Sealing Flange, Front Must sit on alignment pins Removing and installing, refer to «FRONT SEALING FLANGE»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-roadster__front-sealing-flange)

Scheme 79

Scheme 79
Scheme 79

Tighten the oil pan/cylinder block bolts -1 through 20- in a diagonal sequence to 5 Nm.

Tighten the oil pan/transmission bolts -arrows- to 40 Nm.

Tighten the oil pan/cylinder block bolts in a diagonal sequence to 15 Nm.

Scheme 80

Scheme 80
Scheme 80

BALANCE SHAFT MODULE WITH OIL PUMP OVERVIEW

Balance shaft module, refer to OIL PAN OVERVIEW

Oil filter bracket, refer to OIL FILTER BRACKET OVERVIEW

Scheme 81

Scheme 81: BALANCE SHAFT MODULE WITH OIL PUMP OVERVIEW
Scheme 81: BALANCE SHAFT MODULE WITH OIL PUMP OVERVIEW
  1. Chain Guard
  2. Chain Mark direction of travel (installation position) using color marking before removing
  3. Fitting Sleeves
  4. Intermediate Plate
  5. Balance Shaft Module with Oil Pump Before installing, check to be sure both alignment bushings are present (for centering oil pump/cylinder block) Removing and installing, refer to «BALANCE SHAFT MODULE WITH OIL PUMP»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__balance-shaft-module-with-oil-pump)
  6. Bolt 9 Nm
  7. Cover Prevents engine oil from foaming up
  8. Bolt 40 Nm
  9. Bolt 8 Nm
  10. Oil Intake Pipe Clean the screen if it is dirty.
  11. O-ring Replace
  12. Bolt Replace Note different length of bolts (Scheme 82)Tightening sequence (Scheme 83)
  13. Bolt Replace Note different length of bolts (Scheme 82)Tightening sequence (Scheme 83)
  14. Outer Rotor Check contact surfaces for groove build-up Marking must be visible
  15. Inner Rotor Check contact surfaces for groove build-up
  16. Oil Pump Cover
  17. Chain Sprocket
  18. Bolt Replace 20 Nm plus an additional 90° turn
  19. Chain Tensioner with Tensioning Rail Pre-load to install, refer to «CHAIN TENSIONER, TENSIONING»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__chain-tensioner-tensioning)
  20. Bolt 15 Nm

Scheme 82

Scheme 82
Scheme 82

A - Hex collar bolt M7 X 40

B - Hex collar bolt M7 X 70

C - Hex collar bolt M7 X 90

D - Hex collar bolt M7 X 55

E - Sealing plug with O-ring

Scheme 83

Scheme 83
Scheme 83

Hand-tighten bolts -A-.

Tighten the bolts -arrows- in a diagonal sequence from inside to outside to 15 Nm.

Turn bolts -arrows- an additional 90° ( 1 / 4 turn) in a diagonal sequence from inside to outside using a rigid wrench.

OIL FILTER BRACKET OVERVIEW

Oil pan, balance shaft housing, refer to OIL PAN OVERVIEW .

Balance shaft module, oil pump, refer to BALANCE SHAFT MODULE WITH OIL PUMP OVERVIEW .

Scheme 84

Scheme 84: OIL FILTER BRACKET OVERVIEW
Scheme 84: OIL FILTER BRACKET OVERVIEW
  1. Pipe For crankcase ventilation
  2. Oil Pressure Switch -F1- 21 Nm 1.4 bar - black Checking, refer to «OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__oil-pressure-and-oil-pressure-switch)
  3. Screw 15 Nm With Ground (GND) wire for oil pressure switch
  4. Bracket
  5. Bolt 15 Nm
  6. Oil Cooler See note «OIL PAN OVERVIEW»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__oil-pan-overview) Ensure sufficient clearance to surrounding components Coolant hose connection diagram, refer to «COOLANT HOSE CONNECTION DIAGRAM»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-roadster) Removing and Installing, refer to «OIL COOLER»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__oil-cooler)
  7. Gasket Replace
  8. Oil Filter Housing Removing and installing with oil filter wrench 3417 or with socket AF 36, for example socket AF 36 mm T10125 Draining, refer to «OIL FILTER HOUSING, DRAINING»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__oil-filter-housing-draining)
  9. Plug
  10. Seal Replace Lightly lubricate Installed location (Scheme 86)
  11. Oil Filter Element Observe change intervals, refer to Maintenance Procedures.
  12. Bolt 15 Nm
  13. Oil Baffle Installed location (Scheme 85)
  14. Gasket Replace
  15. Oil Filter Bracket Removing and installing, refer to «OIL FILTER BRACKET»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__oil-filter-bracket)

Scheme 85

Scheme 85
Scheme 85

Scheme 86

Scheme 86
Scheme 86

Note the position of the position indicator on the seal -arrow-.

Smooth side of sealing ring must face outward.

CHAIN TENSIONER, TENSIONING

Tension the piston by hand -arrow-.

Scheme 87

Scheme 87: CHAIN TENSIONER, TENSIONING
Scheme 87: CHAIN TENSIONER, TENSIONING

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

Scheme 88

Scheme 88
Scheme 88

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Bracket for Oil Cooler15
Chain Sprocket 120 + 90°
Chain Tensioner with Tensioning Rail15
Cover 2
9
40
Ground (GND) Wire for Oil Pressure Switch15
Oil Drain Plug 130
Oil Filter Bracket15
Oil Intake Pipe8
Oil Pressure Switch21
Oil Pump Cover8
Protective Cap10
1 Always replace 2 For bolt tightening clarification, refer to BALANCE SHAFT MODULE WITH OIL PUMP OVERVIEW and see items -6 and 8

Oil Pan Tightening Sequence

Tighten the oil pan/cylinder block bolts -1 to 20- in a diagonal sequence to 5 Nm.

Tighten the oil pan/transmission bolts -arrows- to 40 Nm.

Tighten the oil pan/cylinder block bolts in a diagonal sequence to 15 Nm.

Bolt Allocation for Balance Shaft Housing

A - Hex collar bolt M7 X 40

B - Hex collar bolt M7 X 70

C - Hex collar bolt M7 X 90

D - Hex collar bolt M7 X 55

E - Sealing plug with O-ring

Balance Shaft Housing Tightening Sequence

1. Hand-tighten bolts -A-.

2. Tighten the bolts -arrows- in a diagonal sequence from inside to outside to 15 Nm.

3. Turn bolts -arrows- an additional 90° ( 1 / 4 turn) in a diagonal sequence from inside to outside using a rigid wrench.

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 Set V.A.G 1594 C

Test Prerequisites

  1. Engine oil level OK, checking, refer to Maintenance Procedures.
  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»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__oil-filter-bracket-overview)

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

Scheme 89

Scheme 89
Scheme 89

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

Connect brown wire of tester to Ground (GND).

Connect the V.A.G 1527 B using adapter cables from the V.A.G 1594 C to battery positive 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: 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 PAN

Special tools and workshop equipment required

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

Removing

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Scheme 90

Scheme 90
Scheme 90

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Remove center noise insulation fasteners -1 to 4-.

Scheme 91

Scheme 91
Scheme 91

Remove the right noise insulation -arrows-.

Scheme 92

Scheme 92
Scheme 92

Remove noise insulation frame -arrow-.

Scheme 93

Scheme 93
Scheme 93

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

Scheme 94

Scheme 94
Scheme 94

Unfasten air duct from turbocharger -arrows-.

Scheme 95

Scheme 95
Scheme 95

Remove bolts -arrows- and remove air guide pipe.

Scheme 96

Scheme 96
Scheme 96

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

Scheme 97

Scheme 97
Scheme 97

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 98

Scheme 98
Scheme 98

Remove the oil return line from the turbocharger -arrows-.

Drain engine oil.

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

Remove the bolts -1 through 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»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__oil-pan-overview)

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.

WARNINGWear safety glasses.

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

Scheme 99

Scheme 99
Scheme 99

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

Cut the tube nozzle at the front marking (nozzle diameter: approximately 3 mm).

Scheme 100

Scheme 100
Scheme 100

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

Scheme 101

Scheme 101
Scheme 101
  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. (Scheme 79)

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, ASSEMBLING .

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 .

WARNINGOnly turn over the engine at the crankshaft in direction of engine rotation (clockwise).

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 102

Scheme 102
Scheme 102

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

Scheme 103

Scheme 103
Scheme 103

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

Scheme 104

Scheme 104
Scheme 104

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

Scheme 105

Scheme 105
Scheme 105

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

Scheme 106

Scheme 106
Scheme 106

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

Scheme 107

Scheme 107
Scheme 107

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»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__balance-shaft-module-with-oil-pump)
  2. Chain tensioner tensioned, refer to «CHAIN TENSIONER, TENSIONING»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__chain-tensioner-tensioning)

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 108

Scheme 108
Scheme 108

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

Note. Observe the different lengths of bolts, refer to. (Scheme 82). Observe tightening sequence (Scheme 83) 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 109

Scheme 109
Scheme 109

Install oil pump chain sprocket with a 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 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 V.A.G 1921

Removing

WARNINGCover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

Open cap of coolant expansion tank.

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Remove center noise insulation fasteners -1 to 4-.

Remove noise insulation frame -arrow-.

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 110

Scheme 110
Scheme 110

Disconnect coolant hose -1-.

Scheme 111

Scheme 111
Scheme 111

Remove the bolt -2-.

Disconnect coolant hoses -arrows- from coolant pipe.

Scheme 112

Scheme 112
Scheme 112

Remove bolt -1- and remove coolant pipe.

Remove the oil cooler -arrows-.

Scheme 113

Scheme 113
Scheme 113

Installing

Install in reverse order of removal. Note the following

  1. For the correct tightening specifications, refer to «OIL FILTER BRACKET OVERVIEW»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__oil-filter-bracket-overview)
  2. For the correct tightening specifications, refer to «COOLING SYSTEM OVERVIEW»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-roadster__cooling-system-overview)

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 V.A.G 1921
  3. Locking Pin T10060A

Removing

WARNINGCover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

Open cap of coolant expansion tank.

Removing

Disconnect electrical connector on mass airflow (MAF) sensor -G70- -3-.

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Remove center noise insulation fasteners -1 through 4-.

Remove noise insulation frame -arrow-.

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 114

Scheme 114
Scheme 114

Secure tensioning element using the T10060A.

Scheme 115

Scheme 115
Scheme 115

Remove ribbed belt.

Remove ribbed belt tensioner -arrows-.

Scheme 116

Scheme 116
Scheme 116

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 117

Scheme 117
Scheme 117

Unfasten 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»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster__oil-filter-bracket-overview)
  2. For the correct tightening specifications, refer to «COOLING SYSTEM OVERVIEW»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-roadster__cooling-system-overview)

Install the oil baffle OIL FILTER BRACKET OVERVIEW

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

Scheme 118

Scheme 118: SPECIAL TOOLS
Scheme 118: SPECIAL TOOLS

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 1594 C

Special tools and workshop equipment required

Scheme 119

Scheme 119
Scheme 119

Scheme 120

Scheme 120
Scheme 120

Scheme 121

Scheme 121
Scheme 121

Scheme 122

Scheme 122
Scheme 122

Scheme 123

Scheme 123
Scheme 123

Scheme 124

Scheme 124
Scheme 124
  1. Oil Drain Adapter T40057
  2. Hex Ball Socket T10058
  3. Connecting Pin T10027 A
  4. Locking Pin T10060A
  5. Drip Tray VAS 6208
  6. Hose Clip Pliers V.A.G 1921

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