After the horrors of the murple, all this stuff is just minor niggles
Freshly powdercoated sump:
Good crank pulley on the left, less good one on the right. The crank sprocket is very hard high-carbon steel whereas the pulley is much softer so when it was rattling about the sprocket both wore away and displaced the steel of the pulley and ate in to it by a couple of mm. The material which was worn away is visible as rusty dust, but most of it was just smushed around in to the pattern of the sprocket.
Good pulley mounted up.
Replacement fan bearing
The engine is back on the separating table, but the wrong way round
so that I can replace the crank rear main seal as this was leaking quite badly. Audi won't sell you a seal - there isn't even a part number for it. Instead, you have to replace the entire rear plate (for £300) which also requires the upper sump to be removed
Luckily Elring are having none of this silliness and will happily sell you the seal on its own for £25 or so. You just have to use the part number for the 2.5 TDI seal to find it
New seal in place
Drive plate back on with new bolts
Engine spun round and back on the gearbox. I can't attach the converter until the morning as the rear main seal has to sit for 4 hours before the crank can be turned, presumably to allow the material to relax in to position after fitting it.
Pre-filling the gearbox through the oil cooler return. I put 1L in the converter and pump while the sump was off, and put another 8L in like this so the level should be pretty close when it starts up again.
Mannol AG52 again, as the 5HP seems to respond really well to this stuff and its £4 a litre instead of £12 for OE! I have also used Mannol in the diffs (£6 a litre instead of £16) and in the engine too (same price but comes in a barrel instead of a stupid cardboard wine-box). It seems to be well made stuff at sensible prices so is going to be my default choice from now on
