Audi Workshop Service and Repair Manuals

Installing sump (top section) - engines with liquid gasket Special tools and workshop equipment required t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Electronic parts catalogue Procedure Installation is carried out in the reverse order; note the following:   Caution Risk of leaks. It is essential to use a liquid gasket again if sump (bottom section) was previously fitted with such a gasket.   Note Renew gaskets, seals and O-rings.

–  Remove remaining sealant on sump (top section) and cylinder block using rotating plastic brush or similar.   WARNING Protect eyes against injuries. 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 sealant.   Note

Note the use-by date of the sealant. –  Cut off nozzle of tube at front marking (nozzle Ø approx. 3 mm).

Caution Make sure lubrication system is not clogged by excess sealant. The bead of sealant must not be thicker than specified. –  Apply bead of sealant -arrows- onto clean sealing surface of sump (top section) as shown in illustration. l  Thickness of sealant bead: 2 ... 3 mm.   Note t  Take particular care when applying sealant bead in area of sealing flange (gearbox end). t  The sump (top section) must be installed within 5 minutes after applying the sealant. –  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 subframe → Rep. Gr.40. –  Install oil pump → Chapter. –  Install sump (bottom section) → Chapter. –  Install alternator and starter → Rep. Gr.27. –  Install poly V-belt for power steering pump, alternator and viscous fan → Chapter.

–  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support and tighten bolts -arrows- to 28 Nm. –  Fill up with engine oil and check engine oil level → Booklet802. –  Fill up with coolant → Anchor. –  Observe notes on procedures required after connecting battery → Rep. Gr.27. Tightening torques

Component		Nm
Sump (top section) to	Cylinder block, sealing flanges	16
	Gearbox	45
Balance shaft assembly to sump (top section)		22
Torque reaction support to top section of sump		45
Coolant drain pipe to sump		10
Stop for torque reaction support to lock carrier		25
Bracket for air conditioner compressor to:	Sump (top section)	22
	Bracket for power steering pump and oil cooler	22
Air conditioner compressor to bracket		22