Audi Workshop Service and Repair Manuals

Removing and installing sump Special tools and workshop equipment required

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

t  Allen key, long reach -T10058- t  Electric drill with plastic brush attachment t  Sealant → Parts catalogue t  Safety goggles

Removing –  Detach bonnet → Chapter. –  Pull oil dipstick out of guide tube. –  Detach guide tube -1- for oil dipstick (press release tabs). –  Detach oil filler pipe -2- from oil filler reservoir. –  Remove front exhaust pipe with catalytic converter → Chapter.

–  Remove bolt -arrow-, detach connection with guide tube for oil dipstick and oil filler pipe from sump.

–  Remove bolts -arrows- and detach heat shield for drive shaft (right-side).

–  Unplug electrical connector -1- at oil level and oil temperature sender -G266-.

–  Place used oil collection and extraction unit -V.A.G 1782- under engine and drain engine oil. –  Remove bolts securing sump to gearbox -arrows-. –  Unscrew bolts for sump -1- in diagonal sequence and remove. –  Carefully release sump from bonded joint. Installing l  Tightening torque → Chapter Installation is carried out in the reverse order; note the following:   Note Fit new O-ring to dipstick guide tube.

Caution Protect lubrication system against contamination. Cover exposed parts of the engine.   WARNING Protect eyes against injuries. Wear safety goggles. –  Remove sealant residue from sump and cylinder block using rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease.

–  Cut off nozzle of tube at front marking (nozzle Ø approx. 2 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 -arrow- onto clean sealing surface of sump as illustrated. l  Thickness of sealant bead: 2 ... 3 mm   Note t  Take particular care when applying sealant bead in area of sealing flange. t  The sump must be installed within 5 minutes after applying the sealant.

–  Fit sump and tighten bolts → Fig..   Note t  If sump is fitted with engine removed, make sure sump is flush with cylinder block at gearbox end. t  After fitting sump assembly, the sealant must dry for approx. 30 minutes. Then (and only then) fill the engine with engine oil. Remaining installation steps are carried out in reverse sequence; note the following: –  Install heat shield for drive shaft → Rep. gr.39. –  Install connection with guide tube for oil dipstick and oil filler pipe → Fig.. –  Install front exhaust pipe with catalytic converter → Chapter. –  Fill up with engine oil and check engine oil level → Booklet809.