Back on the case again.

Opened up the breather in the vee, and gave that a clean out.
https://live.staticflickr.com/65535/...f38e7e1f1c.jpg

And re-sealed it down again - re-used the original gasket with some sealant. I'm still not quite convinced that it was leaking. Once I've done the sump and oil cooler I'll take a look at the RMS.
https://live.staticflickr.com/65535/...62a3d6e97a.jpg

Next up was the oil cooler to swap out the plastic pipe for a brass one I got from Poland via the Bay.

https://live.staticflickr.com/65535/...d101df388b.jpg

It's fair to say that the old one was being held together by the cooler casting and the block. Toast!
https://live.staticflickr.com/65535/...b3daf97035.jpg

In fairness the oil filter was pretty grim too. Clearly not as new as was claimed.

I'd not appreciated there's a kind of 'figure of eight' rubber gasket also needed. I'm struggling to get a part number for this.

On OEMPC..
Obviously I need item 12, but the other 'figure of eight' gasket doesn't have a reference.
https://live.staticflickr.com/65535/...ea3bdb4875.jpg

I did find this, but couldn't cross reference it to anything.
https://live.staticflickr.com/65535/...74f1fb78f5.jpg

Does anyone have any part reference for this?

Next up the sump during the course of this week.

Its only available as part of a set now - the original 077115441 was superseded a while ago by 077198405 which is three times the price and contains a bunch of o-rings you don't need.

Thanks MikkiJayne - that's very helpful.
Does that kit include the o-ring that goes on the steel coolant pipe the enters the housing for the outside? (Item12).

I noticed OEMPC diagrams are not up to date, but if I google that part I can see images of the exploded part diagram that then shows that kit as item 15A.

Is there a better resource that OEMPC out there?

Thanks,
Brian

Of course it doesn't contain the one o-ring you actually need :ROFL: 077121437 for that - same as is on the link pipe.

Etka is the factory parts catalogue. Mine is very old but there are newer versions around.

Thanks - That's my optimism for you. :ROFL:

There's an accountant somewhere in Audi GmbH, excited that o-ring sales are up threefold..

Herr Buchhalter is probably wondering why they peaked some time in 2019 and then dropped off significantly, conveniently coinciding with me working out what size they are and ordering a bag of 100 generic o-rings for about the price of a single special Audi one :D

Very true :D

That reminds me, I've got a selection box of nitrile o-rings out in the garage. Must dig those out and see if any are potential candidates for the simpler ones.

Might save a suprising amount of money... This is already proving to be a bit of a money pit. The purchase value to transmission rebuild cost ratio is essentially 1:1. That's not a good sign. :ROFL:

Disappointingly the Car-SOS crew have not turned up yet, so in their absence, I'm cracking on.

The engine bay needed a degrease and general clean. For this I broke out the smallest cleaning device I have. It operates on Ice-cream & Fortnite V-Bucks. Works quite well.

https://live.staticflickr.com/65535/...f1bec35271.jpg

End result
https://live.staticflickr.com/65535/...be35e91b52.jpg

The inlet manifold was next to be tackled. As mentioned ealrier one set of flaps was really sticky. Cleaning up the spindles didn't have much effect, and I ended up splitting the casing open.

To give and idea of the stickyness inside, this is how the exterior at the throttle body looks.
https://live.staticflickr.com/65535/...70dfeeb5f5.jpg

I've got a new gasket for the above to collect from Audi on Monday.

Based on the price of it, I'm assumning the parts department has one of those 'hand over' areas, where my humble heap of expensive bits will be lurking under a Audi branded handkechief. Using much drama and fanfair, the parts guy will unveil the parts and present my wife with some flowers. I can't wait.

Lots and lots of penetrating oil later applied to the bushings and it still felt sticky on one side. The shaft can't easily be drifted out, so it was really just a case of cleaning it as best as possible. I did wonder if the flaps themselves were tacky with the oily residue that's coated it.

A bit of aggressive cleaning with oven cleaner & hot water....
https://live.staticflickr.com/65535/...abdc252c47.jpg

After much scubbing and cleaning it's perhaps slightly better. I let it dry and then put some more penetrating oil into the bushings and left it a while.

Today I finsihed off cleaning the inlet manifold parts and decided to re-assemble it.

Applied sealant into the groove of the lower casing. I took the old piece of silicone out carefuly in one piece. It looked like it had been gunned in rather than being an actual gasket, so I decided a sealant would be sufficient.
I'll check in the inlet ports to ensure there's no surplus selant that oozed out of the joint.

https://live.staticflickr.com/65535/...32edefe06c.jpg

Longer term I think I'll keep an eye out for a complete inlet from an S8 being broken.

Lid on, torqued evenly, and the linkages all cleaned and re-assembled. It's better than it was, but time will tell if it's operating properly.

https://live.staticflickr.com/65535/...87735cf23c.jpg

Earlier in the week, I took the sump off as this was leaking to some extent. Initially I was going to take the casting that it mounts to, off as well. However, school boy error - realised I'd mounted the engine stand to a bolt hole of that casting. A bit more examination makes me think the oil is not coming from betwene the crankcase and the lower casting, so I decided to leave it in place.

Sump off
https://live.staticflickr.com/65535/...a70d39ef33.jpg

The strainer was decent condition and not contaminated which was a welcome sight.

The sump was duly cleaned and re-sealed.

Winding things back....
https://live.staticflickr.com/65535/...ea3bdb4875.jpg

I managed to get the figure of 8 shaped seal in the above image. Seemingly this was the last one from the factory... Not sure if that means we are now stuck with US sourced ones from eBay. I've not checked Tradition as yet.

Next week I should hopefully be re-installing the inlet manifold, and the oil filter/cooler assembly. Might splash out on some service items next or take a look at the timing chains.

All this is stalling tactics before having to give the transmission over to a specialist..

Brian

Did you find 077115441 in the UK? I thought I'd used them all :rolleyes: I tend to order a few at a time from Tradition when I can, rather than buying the full set, but afaik that set is still available here.

I got 077198405, the set that superceeded it. As far as I know it came from the factory. That's good if Tradition have as it would be a bit of a mission to superglue that together from lengths of o-ring material. :D