Audi Workshop Service and Repair Manuals

Removing and installing sump

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Allen key, long reach -T10058-

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

t	Workshop hoist -VAS 6100-

t	Mud wing compensation plate -T40045-

t	Electric drill with plastic brush attachment

t	Safety goggles

t	Sealant → Parts catalogue

Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing.

–  Pull off engine cover panel -arrows-.

–  Remove the rubber sealing strip from the edges of the wing mounting flanges. –  Place compensation plates -T40045- between the wing mounting flange and the body flange underneath, so that the support bracket -10-222 A- does not damage the edges of the wings.

–  Set up support bracket -10-222 A- with adapters -10-222/3- on wing panel flanges. –  Attach spindles to the engine lifting eyes as illustrated. –  Use spindles to slightly take up weight of engine. –  Remove poly V-belt → Chapter.

–  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-release fasteners -1- and -2- and take off front noise insulation. –  If fitted, open quick-release fasteners -3- and remove rear noise insulation. –  Place used oil collection and extraction unit -V.A.G 1782- under engine and drain engine oil.

–  Unscrew bolts -arrows- and remove torque reaction support from sump. –  Unscrew oil return pipe -1- from turbocharger at sump.

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

–  Unbolt refrigerant pipe bracket from sump -arrow-.

–  Unplug electrical connector -1- for magnetic clutch on air conditioner compressor.   Caution The air conditioner refrigerant circuit must not be opened. –  Unscrew air conditioner compressor from bracket -arrows-.   Note To prevent damage to the condenser and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent. –  Tie up air conditioner compressor to bottom of vehicle, with lines attached.

–  Unplug electrical connector -arrow- at front left vehicle level sender -G78-.

–  Unbolt anti-roll bar mountings -1- and -2-.

–  Support subframe using workshop hoist -VAS 6100- or -V.A.G 1202 A-.

–  Cut open the cable ties -arrows-, open bracket for starter wire and take out the electrical wire.

–  Unscrew nut -3- at bottom of engine mounting. –  Unscrew bolts -4- and -5- on console for engine mounting. –  Unscrew bolt -1- (front) for subframe and remove console for engine mounting -2-. –  Repeat procedure on other side of vehicle.

–  Carefully lower subframe using workshop hoist -VAS 6100- or -V.A.G 1202 A-. –  Lift engine up slightly using spindles of support bracket -10-222 A-; make sure the selector linkage and exhaust system do not become trapped.

–  Unscrew gearbox/sump bolts -arrows-.

–  Unscrew M10 bolts -arrows-. –  Slacken bolts -1 ... 18- in diagonal sequence. –  Take off sump; if necessary loosen it by striking lightly with a rubber hammer. Installing Installation is carried out in the reverse order; note the following: l  Tightening torques → Chapter „Part I: Sump, balance shaft assembly - exploded view“   Note t  Renew seal. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  Fit all cable ties in the original positions when installing.

–  Remove sealant residue from sump and cylinder block with rotating plastic brush or similar.   WARNING Wear safety goggles. –  Clean sealing surfaces; they must be free of oil and grease.   Note t  Sealant bead must not be wider than 3 mm, otherwise excess sealant could ingress into sump and clog strainer in oil intake pipe. t  Take particular care when applying sealant bead in area of rear sealing flange -arrows-. t  The sump must be installed within 5 minutes after applying sealant.

–  Cut off tube nozzle at front marking (nozzle approx. 2 mm Ø).

–  Apply bead of sealant onto the clean sealing surface of the sump as shown in the illustration. l  Thickness of sealant bead: 2 ... 3 mm   Note

t  When installing the sump -3- with the engine removed from the vehicle, make sure that it is positioned flush with the intermediate plate -1- at the flywheel end. In other words, the sump should protrude by 0.8 mm (distance -a-) from cylinder block -2-. t  After fitting sump assembly, the sealant must dry for approx. 30 minutes. Then (and only then) fill the engine with engine oil. –  Immediately fit sump and tighten bolts; tightening sequence → Fig.. –  Install subframe → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install anti-roll bar → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install air conditioner compressor → Rep. Gr.87. –  Install poly V-belt → Chapter. –  Fill up with engine oil and check oil level. Further assembly is basically carried out in reverse order of dismantling.