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TSB audi oil sludge repair .pdf



Original filename: TSB audi oil sludge repair.pdf
Title: a170403 Engine, Oil Pressure Low 1997-2004 Ar (Eng. Codes AEB, AMB, ATW & AWM) 2003-2004 Cabriolet (Eng. Code AMB)
Author: burstac

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Important!

Technical Bulletin

Please give copies to
all your Audi Technicians
Subject:

Engine, Oil Pressure Low

Model(s):

A4 (Eng. Codes AEB, AMB,
ATW & AWM)
Cabriolet (Eng. Code AMB)

Group: 17
Number: 04–03

1997 ä 2004
2003 ä 2004

Date: Aug.

05, 2004

Condition
z Low engine oil pressure light is ON

Service
z Preliminary diagnosis reveals actual low
engine oil pressure condition (engine oil level
is OK and oil pressure switch, instrument
cluster, wiring harness, etc. are OK).
– Remove valve cover.
– Inspect camshafts bearings (Remove only
one cap at a time) for damage.
If ALL camshaft bearings are OK (NOT
damaged):
– Engine must be repaired as described in
“Engine repair guidelines” section.
If one or more camshaft bearings are
damaged:
– Complete engine must be replaced as
described
in “Engine
replacement
guidelines” section.
Note:
Requires FOM
replacement.

authorization

for

engine

Engine repair guidelines:
If no camshaft bearings are damaged:
– Inspect camshaft chain tensioner for visible
damage on the pads in contact with the
chain. Replace tensioner as necessary.
– Remove oil pan.
– Inspect for oil sludge or solid deposits in oil
pan, valve cover and around camshafts.

C 17–04–03
E 2004 Audi of America, Inc. All rights reserved.

1 of 8
Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of

Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Important!

Technical Bulletin

Please give copies to
all your Audi Technicians

If oil sludge or heavy oil deposits are NOT
present:
– Inspect engine oil pump suction line strainer
for obstruction (use background lighting if
necessary).
If engine oil pump suction line strainer is NOT
obstructed:
z Further diagnosis is required to find the
cause of low engine oil pressure.
– Repair as necessary (please see AESIS for
more information).
If oil sludge or substantial oil deposits are
found:
– Remove as much of these deposits from the
engine as possible using mechanical
methods such as scraping (DO NOT leave
loose oil deposits “clumps” in engine)
Note:
ONLY the valve cover and oil pan may be
cleaned with chemical products.
DO NOT attempt to clean the engine with
chemical flushes or similar products.
Ensure that crankcase vent system port on
the valve cover is open and free of
restrictions. Methods for cleaning such as hot
tank, caustic bath and ultrasonic may be
necessary to ensure complete cleaning of this
recessed port. If port is restricted and
cleaning methods are not available, it may be
necessary to replace the valve cover.
If engine oil pump suction line strainer is
blocked by solid particles, or oil sludge or
heavy oil deposits are found inside the
engine:
– Replace Oil Pump suction line (or oil pump
for AEB and ATW engines).
– Replace oil feed and oil return lines to
turbocharger.

C 17–04–03
E 2004 Audi of America, Inc. All rights reserved.

2 of 8
Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of

Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Important!

Technical Bulletin

Please give copies to
all your Audi Technicians
AEB, ATW

Engine code AEB, ATW
– Replace crankcase ventilation system hoses
and pressure regulating valve depending on
engine code (see circled items and compare
to latest illustration on ETKA).
z Replace O-rings, clamps and miscellaneous
fasteners only as necessary.

17-A054

AMB ä VIN:8E 3 040000,
AWM

Engine code AMB ä VIN:8E 3 040000, AWM
– Replace crankcase ventilation system hoses
and pressure regulating valve depending on
engine code (see circled items and compare
to latest illustration on ETKA).
z Replace O-rings, clamps and miscellaneous
fasteners only as necessary.

17-A055

C 17–04–03
E 2004 Audi of America, Inc. All rights reserved.

3 of 8
Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of

Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Important!

Technical Bulletin

Please give copies to
all your Audi Technicians
AMB VIN:8E 3 040001 ä

Engine code AMB VIN:8E 3 040001 ä
– Replace crankcase ventilation system hoses
and pressure regulating valve depending on
engine code (see circled items and compare
to latest illustration on ETKA).
z Replace O-rings, clamps and miscellaneous
fasteners only as necessary.

17-A056

AEB, ATW, AWM,
(AMB ä VIN: 8E 3 040000)

Engine code AEB, ATW, AWM, (AMB ä
VIN: 8E 3 040000)
– Replace crankcase ventilation valve and
hoses.
z Replace O-rings, clamps and miscellaneous
fasteners only as necessary.

17-A057

C 17–04–03
E 2004 Audi of America, Inc. All rights reserved.

4 of 8
Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of

Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Important!

Technical Bulletin

Please give copies to
all your Audi Technicians
AEB, ATW, AWM,
(AMB to VIN: 8E 3 100001)

z For vehicles to MY03 VIN: 8E3100000:
– Inspect and replace brake booster suction jet
pump (circled) if clogged.
z Replace O-rings, clamps and miscellaneous
fasteners only as necessary.

17-A058

– Visually inspect interior of oil filter holder
through crankcase ventilation system line
opening (at top of holder), if excessive oil
deposits are are found, clean as necessary.
– Replace oil filter.
– Install oil pan, but leave engine in “service
position”.
– Fill engine with fresh engine oil.
CAUTION!
For following repair steps:
The engine must be able to run for an
extended period of time, but it is not yet
necessary to restore the vehicle in full
driving conditions.
Ensure Engine and transmission are
adequately supported!

C 17–04–03
E 2004 Audi of America, Inc. All rights reserved.

5 of 8
Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of

Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Important!

Technical Bulletin

Please give copies to
all your Audi Technicians

z With vehicle on a hoist, transmission in
neutral and wheels raised off the ground.
– Start engine and verify that appropriate
engine oil pressure is obtained (see AESIS
for specifications).
CAUTION!
Ensure adequate ventilation to engine
and unrestricted airflow to coolant
radiator.
– Run engine at approx. 3000 RPM for 30
minutes (Tool VAG 1788/10 can be used for
this purpose).
CAUTION!
DO
NOT
leave
engine
running
unattended!
Monitor engine oil pressure throughout
procedure.
z During this time the engine oil must reach a
minimum temperature of 90_C (194_F).
– Switch Ignition OFF.
z With engine still hot.
– Immediately drain engine oil.
z Allow engine to cool to safely continue.
– Remove oil pan and remove/clean any solid
oil residues as necessary.
– Inspect engine oil pump suction line strainer
for obstruction.
If engine oil pump suction line strainer is
blocked or partially blocked by solid particles:
– Clean or replace suction line as necessary.
– Replace oil filter again.
– Install oil pan, fill engine with fresh oil.
– Restore engine
conditions.

C 17–04–03
E 2004 Audi of America, Inc. All rights reserved.

/

vehicle

to

driving

6 of 8
Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of

Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Important!

Technical Bulletin

Please give copies to
all your Audi Technicians

Engine replacement guidelines:
If at least ONE camshaft bearing is damaged:
– Please contact your area FOM for engine
replacement authorization.
With authorization obtained:
– Replace complete engine (head and cylinder
block) using factory remanufactured parts in
accordance to warranty policy.
– Replace turbocharger.
– Replace oil feed and oil return lines of
turbocharger.
– Replace crankcase ventilation system hoses
and pressure regulating valve as described
beginning page 3 (depending on engine
type).
– For vehicles up to MY03 VIN: 8E 3 100 000
Also replace the brake booster suction jet
pump if clogged (see page 5).
– Install new oil filter holder.
– Install new oil cooler.
– Install new oil filter, fill engine with fresh oil
and restore engine / vehicle to driving
conditions.

C 17–04–03
E 2004 Audi of America, Inc. All rights reserved.

7 of 8
Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of

Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Important!

Technical Bulletin

Please give copies to
all your Audi Technicians

WARRANTY:
When ENGINE REPAIR procedure applies
to vehicles within the applicable
Warranty, use the following:
Claim Type:

W2

Damage Code:

S617 10 AUN 1

Labor Operation: S617 8888

900 TU

Includes all operations necessary to
complete described repairs
Input “As per Technical Bulletin
A170403” in comment section of
warranty claim.
When ENGINE REPLACEMENT procedure
applies to vehicles within the applicable
Warranty, use the following:
Claim Type:

W2

Damage Code:

S617 10 AUN 2

Labor Operation: S617 8889

1200 TU

Includes all operations necessary to
complete described repairs
Input “As per Technical Bulletin
A170403” in comment section of
warranty claim.

C 17–04–03
E 2004 Audi of America, Inc. All rights reserved.

8 of 8
Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of

Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.


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