3.2l - Lubrication - Engine Code(s): Cbra (roadster) Audi TT 8J

ENGINE OIL

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

OIL PUMP AND OIL PAN ASSEMBLY OVERVIEW

Note. If a large amount of metal shavings or particles are found when performing engine repairs, these indicate crankshaft or rod bearings are damaged. 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. For engine oil capacities and specifications, refer to the Owner's Manual.

Scheme 125

1. Bolt Fastened to intake manifold 5 Nm
2. Oil Dipstick
3. Guide Tube for Oil Dipstick
4. Cylinder Block
5. Oil Return Valve Removal and installation (Scheme 127)Note installation position
6. Bolt 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. Bolt Insert with locking compound. 10 Nm
13. Oil Spray Jet for Piston Cooling For crankshaft bearing 2 to 7 Opening pressure 2.0 bar pressure Removal and installation (Scheme 128)
14. Oil Pump Driveshaft
15. Oil Pump Disassembling and assembling, refer to «OIL PUMP ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/lubrication-system/#32l-lubrication-engine-codes-cbra-roadster) Coat oil pressure line to cylinder block and at oil pump housing with sealant.
16. Bolt 23 Nm
17. Oil Drain Plug 30 Nm
18. Oil Pan Removal and installation, refer to «OIL PAN»(/audi/tt/8j-2006-2010/remont/lubrication-system/#32l-lubrication-engine-codes-cbra-roadster__oil-pan) Tightening specifications and tightening sequence (Scheme 126)
19. Oil Level Thermal Sensor -G266- Removal and installation (Scheme 129)
20. Bolt Tightening specifications and tightening sequence (Scheme 126)
21. Oil Filter Housing Assembly overview, refer to «OIL COOLER AND OIL FILTER HOUSING ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/lubrication-system/#32l-lubrication-engine-codes-cbra-roadster) Removal and installation, refer to «OIL FILTER HOUSING»(/audi/tt/8j-2006-2010/remont/lubrication-system/#32l-lubrication-engine-codes-cbra-roadster__oil-filter-housing)

Oil Pan - Tightening Specifications and Tightening Sequence

Scheme 126

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 ENGINE, INSTALLING => Manual transmission to engine fastener .

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

Note. Ignore -1-.

Oil Return Valve, Removing and Installing

Scheme 127

Removing

Install M8x1.5 bolt approximately 4 turns into valve -arrow-.

Remove valve.

Installing

Coat O-ring with oil.

Press valve into oil channel by hand.

Oil Spray Nozzle, Removing and Installing

Scheme 128

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

Removing

Press oil spray jet out toward crankshaft bearing with 4 mm diameter drift.

Installing

Press oil spray jet in by hand with 6 mm diameter drift -arrow-.

Oil Level Thermal Sensor -G266-, Removing And Installing

Scheme 129

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

Scheme 130

1. Oil Pump Driveshaft
2. Oil Pump Housing
3. Bolt 23 Nm
4. Gears Backlash, measuring (Scheme 131)Checking axial play (Scheme 132)
5. Oil Pump Cover With check-valve Check-valve opening pressure: 5.3 to 5.7 bar positive pressure Clean strainer if contaminated
6. Bolt Insert with locking compound. 8 Nm
7. Oil Pressure Line Coat at cylinder block and at oil pump housing with sealing paste
8. Bolt 10 Nm
9. Seal Replace if damaged

Backlash, Measuring

Scheme 131

Measure with feeler gauge.

1. Wear limit: 0.20 mm.

Axial Play, Checking

Scheme 132

Measure with feeler gauge and straight edge.

1. Wear limit: 0.10 mm.

Scheme 133

1. Cap 25 Nm
2. O-ring Replace
3. Oil Filter Element Removal and installation
4. Oil Filter Housing With oil check valve
5. Bolt 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/tt/8j-2006-2010/remont/lubrication-system/#32l-lubrication-engine-codes-cbra-roadster__oil-pressure-and-oil-pressure-switch) Removal and installation, refer to «OIL PRESSURE SWITCH»(/audi/tt/8j-2006-2010/remont/lubrication-system/#32l-lubrication-engine-codes-cbra-roadster__oil-pressure-switch) 25 Nm
10. Seals Replace
11. Cap 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/tt/8j-2006-2010/remont/cooling-fan/#32l-cooling-system-engine-codes-cbra-roadster__coolant-hose-connection-diagram) Observe note when repairing engine, refer to «OIL PUMP AND OIL PAN ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/lubrication-system/#32l-lubrication-engine-codes-cbra-roadster__oil-pump-and-oil-pan-assembly)
14. Seal Installed location (Scheme 134)Oil to install Clamp securely on oil cooler with plastic insert -15
15. Plastic Insert Insert into oil cooler together with sealing ring -14-. Installed location (Scheme 134)

Location of Seal and Plastic Insert in Oil Cooler

Scheme 134

Coat sealing ring with oil and insert 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

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 ENGINE, INSTALLING => Manual transmission to engine fastener .

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

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 135

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 (GND).

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

Remove oil dipstick.

Wipe off oil dipstick with a clean cloth and slide back in as far as stop.

Pull oil dipstick back out and check the oil level.

Range of markings on dipstick

Scheme 136

a - Oil must not be added.

b - Oil may be topped off.

c - Oil must be added.

Note. The oil level may not exceed the "max" marking -arrow 1- and fall below the "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
4. Sealant.

Removing

Remove noise insulation in center by loosening mounting parts -1 through 4-.

Scheme 137

Place V.A.G 1782 under engine and drain engine oil.

Remove bolts -1 and 2-.

Scheme 138

Loosen bolt -4- and place secondary air injection (AIR) pump with bracket toward front.

Note. Ignore -3-.

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

Remove oil pan to transmission connection bolts -arrows-.

Loosen oil pan bolts -2- diagonally and remove.

If oil pan is stuck, tap lightly with rubber hammer to loosen.

Installing

1. Tightening specifications, refer to «OIL PUMP AND OIL PAN ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/lubrication-system/#32l-lubrication-engine-codes-cbra-roadster__oil-pump-and-oil-pan-assembly), (Scheme 126).

Installation is in reverse order of removal, note the following

Carefully remove sealant residue on cylinder block.

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

Scheme 139

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

Cut tube nozzle at front marking (jet dia. approximately 1.5 mm).

Scheme 140

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

Scheme 141

1. Thickness of sealant bead: 2 mm.

Note. Be especially careful when applying sealant bead in area of timing chain lower cover. Oil pan must be installed within 5 minutes of applying sealant.

Tighten oil pan -2-. (Scheme 126)

Connect electrical connector -1- on oil level thermal sensor -G266-.

Fill 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

Open coolant reservoir cap.

Disconnect secondary air injection (AIR) hose -arrow-.

Scheme 142

Remove noise insulation in center by loosening mounting parts -1 through 4-.

Free up coolant hose on bottom of fan shroud.

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

In a vehicle with direct shift automatic transmission (DSG), remove bracket -2- for coolant pipe to transmission oil cooler.

Remove bolts -1-.

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

Clamp off coolant hoses -2 and 3- with 3094.

Scheme 143

Disconnect electrical connector -1- on oil pressure switch -F1- with T10118.

Remove coolant hoses -2 and 3- from oil filter housing.

Remove bolts -arrows- and remove oil filter housing.

Installing

1. Tightening specifications, refer to «OIL COOLER AND OIL FILTER HOUSING ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/lubrication-system/#32l-lubrication-engine-codes-cbra-roadster) .

Installation is in reverse order of removal, note the following

Note. Replace the gasket.

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

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 144

Note. Ignore -1 and 4-.

Remove noise insulation in center by loosening mounting parts -1 through 4-.

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

Scheme 145

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 146

Remove oil pressure switch -F1-.

Installing

1. Tightening specifications, refer to «OIL COOLER AND OIL FILTER HOUSING ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/lubrication-system/#32l-lubrication-engine-codes-cbra-roadster) .

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 147

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 148

Scheme 149

Scheme 150

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

See also:
• ENGINE, INSTALLING => Manual transmission to engine fastener
• COOLANT HOSE CONNECTION DIAGRAM
• REMOVAL AND INSTALLATION
• RIBBED BELT
• COOLING SYSTEM, DRAINING AND FILLING => Filling
• OIL PUMP ASSEMBLY OVERVIEW
• OIL PAN
• OIL FILTER HOUSING
• OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING
• OIL PRESSURE SWITCH
• OIL PUMP AND OIL PAN ASSEMBLY OVERVIEW
• OIL LEVEL, CHECKING