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	Removal lever -80-200-

t	Lifting tackle -2024 A-

t	U/J extension and socket, 10 mm -3220-

t	Drip tray -V.A.G 1306-

t

Drip tray

t	Electric drill with plastic brush attachment

t	Safety goggles

t	Sealant → Parts catalogue

Removing l  Lock carrier must be in service position → Chapter.   Note All cable ties which are released or cut open when removing must be refitted in the same position when installing.   Caution Observe notes on procedure for disconnecting the battery → Electrical system; Rep. Gr.27. –  With ignition switched off, disconnect earth strap at battery. –  Drain off coolant → Chapter. –  Remove poly V-belt → Chapter.

–  Disconnect hose -arrow- from secondary air connecting pipe.

–  Pry off retaining clips -2- for wiring harness at air cleaner housing (use removal lever 80-200). –  Detach electrical connector -1- at air mass meter. –  Remove air cleaner housing -arrows-.

–  Remove bolt -arrow-. –  Pull oil dipstick guide tube -2- upwards out of sump (top section), swivel forward and remove.

–  Position support bracket -10-222 A- on bolted flanges of wing panels.

–  Remove lifting eye from lifting tackle -2024 A-. –  Re-insert pin -1- in centre hole of lifting tackle and secure with split pin. –  Hook pin of lifting tackle -2024 A- on spindle of support bracket -10-222 A-. –  Unfasten cable tie at rear engine lifting eye and move wire clear. –  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-. –  Partly take up weight of engine with spindle of support bracket.

–  Remove torque reaction support -arrows-.

–  Place a drip tray underneath. –  Drain off engine oil. –  Remove oil filter -5-. –  Place drip tray -V.A.G 1306- beneath engine. –  Detach coolant hoses -1-, -6- and -7-. –  Remove oil cooler. –  Remove bolts -2- and -3- and detach coolant pipe from sump (top section).

–  Unplug electrical connector -2- at secondary air pump motor -V101--item 1-. –  Detach secondary air pump with bracket from longitudinal member.   WARNING The air conditioner refrigerant circuit must not be opened.

–  Remove bolts -1- and -2-. –  Unclip refrigerant lines -arrows-. –  Detach reservoir -3- and leave suspended in installation position with refrigerant pipes connected.

Vehicles with automatic gearbox 01J: –  Remove retainer for ATF pipes (unscrew nuts -1- and -2-).   Note Take care not to unscrew union nuts -3- for ATF pipes.

All models: –  Unbolt refrigerant pipe bracket from sump -arrow-.   Note Illustration shows vehicle with manual gearbox.

–  Unplug electrical connector -1- for magnetic clutch on air conditioner compressor. –  Unbolt air-conditioner compressor from bracket -arrows-.

–  Tie up A/C compressor -arrow- (pipes connected) to anti-roll bar using wire.

–  Unplug electrical connector -arrow- at oil pressure switch.

–  If fitted, unclip actuator rod for vehicle level sender at bottom transverse link -arrow-.

–  Mark position of nuts -1- and locating sleeves -2- on bottom of engine mountings (right and left).   Note Different mounting holes are provided for the different engine versions. –  Remove bottom nut -1- at engine mountings (left and right).

–  First remove front subframe bolts -2- and -3- (left and right). Then remove bolts -1-.   Note To avoid having to check and adjust wheel alignment, only loosen the front subframe mountings and lower the subframe at the front. –  Lower subframe at the front.

–  Detach wiring at alternator. –  Unscrew bolts -arrows- and remove alternator.

–  Unbolt heat shield -1- for drive shaft (right-side) if necessary.

–  Detach wires -1- and -2- from starter.   Note Do not disconnect earth cable -3-.

–  Pull heat shield -1- off solenoid switch. –  Remove bolts -2- and -3- and detach starter.

–  Unplug electrical connector from oil level sender -arrow- and move wiring clear.

–  Place a drip tray underneath. –  Unbolt sump (bottom section) -1- and remove it carefully. –  Remove oil pump → Chapter.

–  Raise engine slightly using spindle of support bracket -10-222 A-.   Note Make sure that air duct at rear of intake manifold is not damaged when lifting engine.

–  If fitted, open quick-release fasteners -2- and -3- and remove rear noise insulation.

–  Unbolt bracket for noise insulation -arrows-.

–  Unscrew engine/gearbox connecting bolts in area of sump (top section). –  Check whether U/J extension and socket, 10 mm -3220- can be inserted through assembly opening -arrows-. Widen out assembly opening if necessary.

–  Unscrew bolts -1- and -2- for sump (top section). –  Press sump (top section) off spring pins on cylinder block. Installing Installation is carried out in the reverse order; note the following:   Note t  All cable ties which are released or cut open when removing must be refitted in the same position when installing. t  Renew gaskets, seals and self-locking nuts.

–  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.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 1 mm).

–  Apply the bead of sealant onto the clean sealing surface of the sump (top section) as illustrated. l  Bead of sealant should be approx 1.5 mm wide -arrows-.   Note t  The sump (top section) must be installed within 5 minutes after applying sealant. t  The sealant bead must not be thicker than specified, otherwise excess sealant could enter the sump and clog the strainer in the oil pump. t  Apply sealant with particular care around sealing flange -arrows- in cylinder block. –  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- to 16 Nm and bolts -2- to 22 Nm in a diagonal sequence. –  Install oil pump → Chapter. –  Install sump (bottom section) → Chapter. –  Renew O-ring on guide tube for oil dipstick and insert guide tube into hole in top section of sump. –  Install starter → Electrical system; Rep. Gr.27. –  Install alternator → Electrical system; Rep. Gr.27 –  Install subframe → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install air conditioner compressor → Air conditioning system; Rep. Gr.87. –  Install poly V-belt → Anchor. –  Install lock carrier → 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.   Note t  Drained-off coolant may only be used again if the original cylinder head and cylinder block are re-installed. t  Contaminated or dirty coolant must not be used again. Tightening torques

Component		Nm
Sump (top section) to:	M7	16
Cylinder block and sealing flanges	M8	22
Sump (top section) to gearbox		45
Bracket for noise insulation to subframe		10
Engine mounting to subframe		23
Reservoir bracket to body		10
Refrigerant line bracket to sump		10
Secondary air pump bracket to longitudinal member		10
Oil cooler to sump (top section)		30
Guide tube for dipstick to cylinder head		22