Audi Workshop Service and Repair Manuals

Removing and installing sump

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Allen key (long reach) -T10058-

t	Used oil collection and extraction unit -V.A.G 1782-

t	Workshop hoist -VAS 6100-

t	Mud wing compensation plate -T40045-

t	Electric drill with plastic brush attachment

t	Safety goggles

t	Sealant → Electronic parts catalogue

Note t  Removal and installation described in the following applies to vehicles with 5-speed manual gearbox (front-wheel drive) and vehicles with multitronic gearbox. t  On vehicles with 6-speed manual gearbox (front-wheel drive or four-wheel drive), the engine and dual-mass flywheel must be removed. Further instructions → Anchor.

Removing –  Pull dipstick -1- out of guide tube. –  Unclip cover caps. –  Unscrew nuts -arrows- and detach engine cover panel. –  Remove insulation beneath cover. –  Re-insert dipstick in guide tube.

–  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Open quick-release fasteners -1 … 3- and take off front and rear noise insulation.

Vehicles up to 05.2003: –  Remove bumper cover (front) → Rep. Gr.63. –  Move lock carrier to service position → Rep. Gr.50. –  Unscrew bolts -arrows- and remove torque reaction support from sump. Vehicles from 06.2003 onwards: –  Remove poly V-belt → Chapter.

All vehicles: –  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at bottom of expansion tank and move expansion tank to one side with coolant hoses -1- and -2- attached.

–  Unplug electrical connector -1-. –  Move aside fuel hoses at air pipe. –  Remove bolt -2-. –  Remove air pipe -arrows-.

–  Remove the rubber sealing strip from the edges of the wing mounting flanges. –  Place compensation plates -T40045- between the wing mounting flange and the apron underneath, so that the support bracket -10 - 222 A- does not damage the edges of the wings.

–  Set up support bracket -10 - 222 A- with two adapters -10 - 222 A /3- on wing panel flanges. –  Attach spindles to the engine lifting eyes as illustrated. –  Use spindles to slightly take up weight of engine. –  Place used oil collection and extraction unit -V.A.G 1782- under engine and drain engine oil.

–  Unplug electrical connector -arrow- at oil level and oil temperature sender -G266-.

–  Unbolt refrigerant pipe brackets -1- and -2- from sump.

Vehicles from 06.2003 onwards: –  Unplug electrical connector -arrow- at engine mounting (left-side).

–  Unplug electrical connector -1- for magnetic clutch of air conditioner compressor. –  Move wiring harness clear.   Caution The air conditioner refrigerant circuit must not be opened. –  Unscrew air conditioner compressor from bracket -arrows-.   Note To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Tie up air conditioner compressor and condenser with hoses/pipes connected to side of vehicle.

–  Unscrew bolts -arrows- and remove torque reaction support from sump. Vehicles with multitronic gearbox:   Note Observe rules for cleanliness when working on automatic gearbox → Rep. Gr.37. –  Unbolt bracket for ATF pipe at engine.

Vehicles up to 10.2004: –  If fitted, unclip actuator rod for vehicle level sender at bottom transverse link -arrow-.

Vehicles from 11.2004 onwards: –  If fitted, unplug electrical connector -arrow- at front left vehicle level sender -G78-.

All vehicles: –  Unbolt anti-roll bar mountings -1- and -2-.

–  Support subframe using workshop hoist.

–  Cut open the cable ties -arrows-, open bracket for starter wire and take out the electrical wire.   Note To avoid having to check and adjust wheel alignment, only loosen the front subframe mountings and lower the subframe at the front.

–  Unscrew nut -3- at bottom of engine mounting. –  Unscrew bolts -4- and -5- on console for engine mounting. –  Unscrew bolt -1- (front) for subframe and remove console for engine mounting -2-. –  Repeat procedure on other side of vehicle.

–  Carefully lower subframe using workshop hoist.

–  Lift engine up slightly using spindles of support bracket -10 - 222 A-; make sure the selector linkage and exhaust system do not become trapped.

–  Unbolt bracket for noise insulation -arrows-.

–  Unscrew gearbox/sump bolts -arrows-.

–  Unscrew M10 bolts -arrows-. –  Slacken bolts -1 ... 18- in diagonal sequence.   Note

On vehicles with manual gearbox, the two rear sump bolts -1- and -2- are accessible via the recess -arrow- on the dual-mass flywheel -3- (turn the dual-mass flywheel as required). –  Take off sump; if necessary loosen it by striking lightly with a rubber hammer.   Note Detach bolts which cannot be removed together with the sump.

Installing   Note Renew seal.   WARNING Wear safety goggles. –  Remove sealant residue from sump and cylinder block with rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease.

–  Cut off tube nozzle at front marking (nozzle approx. 2 mm Ø).

–  Apply bead of sealant onto the clean sealing surface of the sump as shown in the illustration. l  Thickness of sealant bead: 2 ... 3 mm   Note t  Sealant bead must not be wider than 3 mm, otherwise excess sealant could ingress into sump and clog strainer in oil intake pipe. t  Take particular care when applying sealant bead in area of rear sealing flange -arrows-. t  The sump must be installed within 5 minutes after applying sealant.

–  Immediately install sump and tighten all bolts in the following sequence: 1.  Pre-tighten bolts -1 ... 18- in diagonal sequence to 5 Nm. 2.  Tighten bolts securing sump to gearbox to 45 Nm. 3.  Tighten bolts M10 -arrows- to 40 Nm. 4.  Tighten bolts -1 ... 18- in diagonal sequence to 15 Nm.   Note

t  When installing the sump -3- with the engine removed from the vehicle, make sure that it is positioned flush with the intermediate plate -1- at the flywheel end. In other words, the sump should protrude by 0.8 mm (distance -a-) from cylinder block -2-. t  After fitting sump assembly, the sealant must dry for approx. 30 minutes. Then (and only then) fill the engine with engine oil. The remaining installation steps are carried out in the reverse sequence. –  Install subframe → Rep. Gr.40. –  Install anti-roll bar → Rep. Gr.40. –  Secure ATF lines → Rep. Gr.37. –  Install air conditioner compressor → Rep. Gr.87. –  Install lock carrier with attachments → Rep. Gr.50.

–  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten bolts -arrows-. –  Install bumper cover (front) → Rep. Gr.63. –  Fill up with engine oil and check oil level → Booklet803 or → Booklet805. Tightening torques

Component		Nm
Sump to:	M7	15
Cylinder block	M10	40
Sump to gearbox		45
Engine mounting to subframe		23
Engine mounting to engine support		23
Oil drain plug		30
Stop for torque reaction support to sump - vehicles up to 05.2003		28
Torque reaction support to sump - vehicles from 06.2003 onwards		23