Audi Workshop Service and Repair Manuals

Removing and installing sump

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Socket -3249- or -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  Lifting tackle -2024 A-

Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Release quick fasteners -arrows- and remove engine cover panel.

–  If fitted, detach cover -1- on right of engine compartment.

–  Disengage solenoid valve 1 for activated charcoal filter system -N80- at air duct. –  Remove bolts -arrows-. –  Remove air duct -2-.   Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  Turn the tensioner in the direction of the -arrow- to slacken the poly V-belt. –  Remove poly V-belt from alternator pulley. –  Release tensioner. –  Remove poly V-belt completely.   Note Unscrew securing bolts of tensioner a few turns if poly V-belt cannot be removed from pulley.

–  Pull off bonnet seal at wing mounting flanges. –  Place compensation plates -10-222 A- between the wing mounting flange and the body flange underneath, so that the support bracket -T40045- does not damage the wing mounting flanges.

–  Set up support bracket -10-222 A- on wing panel flanges.

–  Remove eyelet of lifting tackle -2024 A-. –  Re-insert pin -1- in centre hole of lifting tackle and secure with split pin. –  Hang the pin of lifting tackle -2024 A- onto the spindle of support bracket -10-222 A-.

–  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-. –  Take up weight of engine using support bracket spindle (do not raise).

–  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.

–  Unbolt bracket for noise insulation -arrows-.

–  Place used oil collection and extraction unit -V.A.G 1782- under engine and drain engine oil. –  Remove oil return pipe from sump (unscrew bolts -arrows-).

–  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 refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Tie up air conditioner compressor to vehicle, with lines attached.

–  Unscrew bolts -arrows- and remove torque reaction support.

–  If fitted, unclip actuator rod for vehicle level sender (front left) -G78- at bottom transverse link -arrow-.

–  Remove bolts -1- and -2- from anti-roll bar mounting.

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

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

–  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 spindle 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.   Note

Use hexagon key extension -3249- or -T10058- to unscrew the two rear sump bolts -1- and -2-. For this purpose, turn the dual-mass flywheel -3- (on vehicles with manual gearbox) until the recess -arrow- is aligned with the bolt. –  Remove all bolts and 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:   Note t  Renew gaskets and seals. t  Fit all cable ties in the original positions when installing. –  Carefully remove sealant residues from cylinder block. For this purpose, remove baffle plate. –  Remove sealant residue from sump, e.g. with rotating plastic brush or similar.   WARNING Wear safety goggles. –  Clean sealing surfaces; they must be free of oil and grease.

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

–  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  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  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.

–  Immediately install sump and tighten bolts in the sequence indicated: 1.  Pre-tighten bolts -1 ... 18- to 5 Nm in diagonal sequence. 2.  Tighten bolts securing sump to gearbox to 45 Nm. 3.  Tighten bolts M10 -arrows- to 40 Nm. 4.  Tighten bolts -1 ... 18- to 15 Nm in diagonal sequence.   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. –  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 → Air conditioning system; Rep. gr.87. –  Install poly V-belt → Chapter. –  Fill up with engine oil and check oil level. Tightening torques

Component		Nm
Sump to:	M7	15
Cylinder block	M10	40
Sump to gearbox		45
Oil return pipe to sump		10
Torque reaction support to sump		23
Engine mounting to subframe		23
Oil drain plug		30