Audi TT (2007 year). Manual — part 38
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
Note the use-by date of the sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2
mm).
Caution
Make sure lubrication system is not clogged by excess sealant.
♦ The bead of sealant must not be thicker than specified.
– Apply bead of sealant onto clean sealing surface of sump as
illustrated.
• Thickness of sealant bead: 2 ... 3 mm
Note
♦
Take particular care when applying sealant bead in area of
rear sealing flange -arrows-.
♦
The sump must be installed within 5 minutes after applying the
sealant.
• The sump must make flush contact with intermediate plate/
gearbox flange.
Note
♦
When installing sump with engine removed from vehicle, en‐
sure that sump is positioned flush with cylinder block at gear‐
box end.
♦
After fitting sump assembly, the sealant must dry for approx.
30 minutes. Then (and only then) fill the engine with engine
oil.
– Install pump for exhaust gas recirculation cooler -V400-
– Install air pipe (left-side)
.
– Install air hose with plug-in connector
810 .
1. Oil pump, sump, balance shaft assembly
143
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
1.4
Removing and installing oil pump
Special tools and workshop equipment required
♦ Circlip pliers, commercially available
♦ Bolt M3
Removing
– Remove sump
.
– Remove bolts -arrows- and detach suction pipe from oil pump.
– Remove circlip -1- using circlip pliers.
– Screw in an M3 bolt -2- and pull drive shaft out of oil pump
-arrow-.
– Remove bolts -3, 4, 5- and detach oil pump.
Caution
The bolt on the idler gear must NOT be loosened.
Installing
• Tightening torque
.
Installation is carried out in the reverse order; note the following:
Note
♦
Fit new O-ring.
♦
Renew circlip if damaged or stretched.
♦
Circlip must fit securely in groove.
– If no dowel sleeves for centring the oil pump are fitted in the
balance shaft assembly, install missing dowel sleeves.
– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
810 .
1.5
Removing balance shaft assembly
Special tools and workshop equipment required
144
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Crankshaft stop -T10050-
Procedure
– Remove vibration damper
Caution
Irreparable damage can be caused if the toothed belt slips.
♦ Turn crankshaft only in direction of engine rotation.
– Rotate crankshaft by turning bolt for toothed belt sprocket until
crankshaft is positioned at “TDC”.
– Lock crankshaft in position with crankshaft stop -T10050- .
• The markings on the sprocket -2- and the crankshaft stop -1-
must align -arrow-. The pin of the crankshaft stop must engage
in the aperture in the sealing flange.
Note
The crankshaft stop can only be pushed onto the sprocket from
the front face of the teeth.
– Loosen bolts in the sequence -8 ... 1-.
– Remove bolts and detach balance shaft assembly with oil
pump.
Note
♦
Installing a new balance shaft assembly
.
♦
Re-installing a used balance shaft assembly
1. Oil pump, sump, balance shaft assembly
145
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
1.6
Installing a new balance shaft assembly
Special tools and workshop equipment required
♦ Bits -T10099-
♦ Locking tool -T10255-
♦ Special tool -T10393-
Procedure
• Tightening torques
• Crankshaft locked in position with crankshaft stop -T10050- .
Note
♦
The spur gear drive of the balance shaft assembly must be
installed with a backlash of 0.038 ... 0.072 mm.
♦
To achieve the correct backlash, a suitably thick coating is al‐
ready applied to the new idler gear.
♦
The coating is worn down rapidly and the backlash is then
correct.
♦
On idler gears with coating applied to teeth on parts of cir‐
cumference only, a white dot indicates correct installation
position.
♦
If there is no white dot, the complete circumference of the idler
gear is coated.
♦
A new balance shaft assembly must always be installed in
conjunction with a new idler gear which has the correct coat‐
ing.
♦
Renew bolts securing balance shaft assembly.
146
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