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.

– Fit sump and tighten bolts 

⇒ page 138

 .

• 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-

⇒ page 175

 .

– Install air pipe (left-side) 

⇒ page 208

 .

– Install air hose with plug-in connector 

⇒ page 209

 .

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 

⇒ page 139

 .

– 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 

⇒ page 136

 .

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.

– Install sump 

⇒ page 139

 .

– 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 

⇒ page 49

 .

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.

– Remove sump 

⇒ page 139

 .

– Loosen bolts in the sequence -8 ... 1-.
– Remove bolts and detach balance shaft assembly with oil

pump.

Note

♦

Installing a new balance shaft assembly 

⇒ page 146

 .

♦

Re-installing a used balance shaft assembly 

⇒ page 149

 .

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 

⇒ page 136

• 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