Audi Workshop Service and Repair Manuals

Removing and installing sump (top section)

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Lifting tackle -2024 A-

t	Workshop hoist -VAS 6100- or -V.A.G 1202 A-

t	Drip tray for workshop hoist -VAS 6208- or -V.A.G 1306-

t  Mud wing compensation plate -T40045- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Parts catalogue Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing.   Caution Observe notes on procedure for disconnecting the battery → Electrical system; Rep. Gr.27. –  Disconnect earth wire at battery with ignition switched off.

–  Pull off engine cover panel -arrows-.

–  Pull off bonnet seal at wing mounting flanges. –  Place compensation plates -T40045- between the wing mounting flange and the body panel underneath, so that the support bracket -10-222 A- does not damage the wing mounting flanges.

–  Position support bracket -10-222 A- on wing mounting flanges (spindle faces to front).

–  Remove eyelet of lifting tackle -2024 A-. –  Re-insert pin -1- in centre hole of lifting tackle -2024 A- and secure with split pin. –  Hang the pin of lifting tackle -2024 A- onto the spindle of support bracket -10-222 A-. –  Engage lifting tackle -2024 A- in front and rear lifting eyes on engine.   WARNING The support hooks and retaining pins on the lifting tackle must be secured with locking pins -arrows-. –  Take up weight of engine using spindle on support bracket -10-222 A- (do not lift engine). –  Pull out oil dipstick. –  Unbolt dipstick guide tube on cylinder head (right-side).

–  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.

–  Unbolt bracket for noise insulation -arrows-.

–  Remove nuts -arrows- on stop for torque reaction support.

–  Unscrew bolts -arrows- and remove torque reaction support together with stop for torque reaction support. –  Remove poly V-belt for power steering pump, alternator and viscous fan → Chapter

–  Unplug electrical connector -1- at air conditioner compressor regulating valve -N280-.   WARNING The air conditioner refrigerant circuit must not be opened. –  Remove bolts -arrows- for air conditioner compressor.   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 onto subframe, leaving refrigerant lines connected -arrow-.

–  Unbolt bracket for A/C compressor -arrows-.

–  Unplug electrical connector -arrow- at engine mounting (right-side). –  Move wiring clear.

–  Remove bolts -arrows-. –  Pivot alternator to front and unscrew electrical wires.

–  Detach electrical wires -2- and -3- at starter. –  Remove starter bolts -arrows- from gearbox side. –  Detach starter.   Note Disregard -item 1-.

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: –  Remove bolts -1- and -2- from anti-roll bar mounting.

–  Cut open the cable ties -arrows-, open bracket for starter wire and take out the electrical wire.

–  Support subframe using workshop hoist -VAS 6100- or -V.A.G 1202 A-.

–  Unscrew nut -3- at bottom of engine mounting. –  Unscrew bolts -4- and -5- on console for engine mounting.   Note To avoid having to check and adjust wheel alignment, only loosen the front subframe mountings and lower the subframe at the front. –  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 -VAS 6100- or -V.A.G 1202 A-. –  Pull the workshop hoist from beneath the vehicle.

–  Lift engine up slightly using spindles of support bracket -10-222 A-; make sure the selector linkage and exhaust system do not become trapped. –  Remove sump (bottom section) → Chapter. –  Remove oil pump → Chapter.

–  Unscrew gearbox/sump bolts -arrows-. –  Unscrew engine/gearbox connecting bolts in area of sump (top section). –  Press dipstick guide tube out of sump (top section).

–  Unscrew bolts -1- and -2- for sump (top section). –  Press sump (top section) off spring pins on cylinder block. –  Push sump (top section) to left side of vehicle and take out.

–  Unscrew bolts -arrows- and remove balance shaft housing from sump (top section). Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seals and O-rings. t  Fit all cable ties in the original positions when installing.

–  Remove remaining sealant on sump (top section) and cylinder block using rotating plastic brush or similar.   WARNING Wear safety goggles. –  Clean sealing surfaces; they must be free of oil and grease.   Note The sump (top section) must be installed within 5 minutes after applying the silicone sealant.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 3 mm).

–  Apply the bead of silicone sealant onto the clean sealing surface of the sump (top section), as illustrated. l  Width of sealant bead -arrows-: 2 ... 3 mm.   Note t  The sealant beads must not be thicker than specified, otherwise excess sealant could enter the sump and clog the strainer in the oil pump. t  Take particular care when applying sealant bead in area of rear sealing flange. –  Fit new O-ring to dipstick guide tube. –  When positioning sump (top section), insert dipstick guide tube in hole. –  Fit sump (top section) and tighten all bolts securing sump (top section) to cylinder block initially to 5 Nm in diagonal sequence. –  Tighten bolts securing sump (top section) to gearbox to 45 Nm.

–  Tighten bolts -1- and -2- securing sump (top section) to cylinder block in diagonal sequence to 16 Nm. –  Install oil pump → Chapter. –  Install sump (bottom section) → Anchor. –  Install subframe → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install anti-roll bar → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install starter → Electrical system; Rep. Gr.27. –  Install alternator → Electrical system; Rep. Gr.27 –  Install air conditioner compressor → Air conditioning system; Rep. Gr.87. –  Install poly V-belt for power steering pump, alternator and viscous fan. → Anchor

–  Fit torque reaction support together with stop for torque reaction support and tighten bolts -arrows-.

–  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten nuts -arrows-. –  Install radiator cowl → Chapter. –  Install viscous fan → Chapter. –  Fill up with engine oil and check oil level → Chapter. –  Observe notes on procedures required after connecting battery → Electrical system; Rep. Gr.27. –  Fill cooling system → Anchor. Tightening torques

Component		Nm
Balance shaft housing to sump (top section)		22
Sump (top section) to:	Cylinder block and sealing flanges	16
	Gearbox	45 → Note
Console for engine mounting to longitudinal member		75
Engine mounting to console for engine mounting		23
Bracket for A/C compressor to:	Sump (top section)	22
	Bracket for power steering pump and oil cooler	22
Torque reaction support to top section of sump		40
Stop for torque reaction support		28

1)  Renew bolts on vehicles with multitronic gearbox.