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  Safety goggles t  Sealant → Electronic parts catalogue

Removing –  Remove front exhaust pipe → Chapter. –  Unplug electrical connector -1- at oil level and oil temperature sender -G266-.   Note Disregard -item 2-.

–  Remove bolts -1- and -2- and press coolant pipe to the right.   Note Disregard -arrows-.

–  Place used oil collection and extraction unit -V.A.G 1782- below engine and drain off 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 → Fig.   Caution Take care to keep cylinder block clean. Cover exposed parts of the engine. –  Machine intermediate plate between engine and gearbox to dimension -a- as shown in illustration. l  Distance -a- = 5 mm.   Note It is not possible for fit sump with sealant bead onto cylinder block without machining the intermediate plate.

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 coolant pipe (right-side) → Chapter. –  Install front exhaust pipe → Chapter. –  Fill with engine oil and check oil level → Chapter.