Audi Workshop Service and Repair Manuals

Removing and installing sump (top section) Special tools and workshop equipment required t  Assembly tool -T10118- t  Brake pad wear tester -VW 136- t  Torque wrench -V.A.G 1331- t  Electric drill with plastic brush t  Safety goggles t  Silicone sealant → Electronic parts catalogue Removing –  Remove gearbox → Rep. Gr.34. –  Remove sump (bottom section) → Chapter. –  Remove oil pump → Chapter. –  Remove sealing flange (gearbox end) → Chapter. –  Remove wheel housing liner (front section, right section-side) → General body repairs - exterior; Rep. Gr.66.

–  Remove bolts -arrows-. –  Remove air pipe (lift clips -1 and 2-).

–  Unscrew bolt -1- –  Remove wire retainer next to continued coolant circulation pump -V51- from sump (top section).

–  Unplug electrical connector -1-.

–  Remove bolts -arrows-.   DANGER! Injury risk! The chain tensioner spring for oil pump drive jumps from sump (top section) to timing chain cover (bottom) when detaching sump (top section). Do not reach between sump (top section) and timing chain cover (bottom) when removing sump (top section).

–  Remove bolts -1 to 14- and lever off sump (top section).   Caution Lever off sump (top section) at gearbox end first. Take care timing chain cover is not bent when levering off. Installing l  Tightening torque → Chapter „Sump, oil pump - exploded view“ t  Silicone sealant → Electronic parts catalogue   Note t  Note the expiry date of the silicone sealant. t  The sump (top section) must be installed within 5 minutes after applying silicone sealant.

–  Use assembly tool -T10118- to pull chain tensioner spring for oil pump drive in direction of guide rail -arrow-. –  Secure spring by inserting brake pad wear tester -VW 136- into opening in guide rail as shown in illustration. –  Remove sealant remaining on cylinder block with flat scraper.   WARNING Protect eyes against injuries. Wear safety goggles.

–  Remove residual sealant at sump (top section) and timing chain cover (bottom) e.g. using a rotating plastic brush.   Note Check if timing chain cover is deformed. For this purpose, first fit sump (top section) without sealant and determine gap between cover and sump (top section). If the cover is deformed and cannot be straightened, renew cover after installing sump (top section). –  Clean sealing surfaces; they must be free of oil and grease. –  Check oil channels in sump (top section) and crankcase for contamination.

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

–  Apply bead of silicone sealant onto clean sealing surfaces of sump (top section) and timing chain cover (bottom) as shown in illustration -arrows-   Caution Make sure lubrication system is not clogged by excess sealant. The bead of sealant must not be thicker than specified. t  Thickness of sealant bead: 2 ... 3 mm   Note t  The sump (top section) must be installed within 5 minutes after applying silicone sealant. t  The bead of sealant must not be thicker than specified, otherwise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe. l  Sump (top section) and crankcase must be flush at gearbox end. –  Immediately fit sump (top section) and tighten bolts, tightening torque → Fig..

–  Fit bolts -arrows-. Tightening torque → Item

–  Pull brake pad wear tester -VW 136- out of guide rail -arrow-. The spring now returns to installation position. –  Install sealing flange (gearbox end) → Chapter. –  Install oil pump → Chapter. –  Renew baffle plate. –  Install sump (bottom section) → Chapter. –  Fill with engine oil and check oil level → Booklet808. Further assembly is basically carried out in reverse order of dismantling.