Audi Workshop Service and Repair Manuals

Removing and installing sump (top section)

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Lifting tackle -2024 A-

t	Hose clamps for hoses up to 25 mm Ø -3094-

t	U/J extension and socket, 10 mm -3220-

t	Drip tray for workshop hoist -VAS 6208- or -V.A.G 1306-

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

t  Mud wing compensation plate -T40045- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Parts catalogue

Removing –  Move lock carrier to service position → Chapter.   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  With ignition switched off, disconnect earth strap at battery. –  Remove poly V-belt → Chapter. –  Remove air cleaner housing -arrows-.

–  Remove bolts -1- and -3-. –  Disconnect hose -4- at pipe for secondary air. –  Pull guide tube -2- for oil dipstick upwards out of top section of sump and fold forwards.

–  Pull off bonnet seal at wing mounting flanges. –  Place compensation plates -T40045- between the wing mounting flange and the body panel underneath, so that the support bracket -10-222 A- 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 spindle of support bracket. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Drain off engine oil.

–  Loosen oil filter -arrow- using oil filter tool -3417-.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Clamp off coolant hoses -2- and -3- using hose clamps -3094-. –  Disconnect coolant hoses from oil cooler -1-. –  Remove oil cooler.

–  Unplug electrical connector -2- at secondary air pump motor -V101--item 1-. –  Detach secondary air pump from longitudinal member.   Note

To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent.   WARNING The air conditioner refrigerant circuit must not be opened. –  Remove bolts -1- and -2-. –  Unclip refrigerant lines -arrows-. –  Leave air conditioner receiver -3- suspended in position with refrigerant pipes connected.

Vehicles with multitronic gearbox 01J or automatic gearbox 01V: –  Remove retainer for ATF pipes (unscrew nuts -1- and -2-).   Note Take care not to unscrew union nuts -3- for ATF pipes.

All vehicles: –  Unbolt refrigerant pipe bracket from sump -arrow-.   Note Illustration shows vehicle with manual gearbox.

–  Unplug electrical connector -1- for magnetic clutch of air conditioner compressor. –  Unscrew air conditioner compressor from bracket -arrows-.

–  Tie up A/C compressor -arrow- (pipes connected) to anti-roll bar using wire.

–  Mark positions of bolt connections -1- and locating sleeves -2- on bottom of engine mountings (left and right).   Note Different mounting holes are provided for the different engine versions. –  Unscrew nuts -1- (bottom) at engine mountings (left and right).

–  If fitted, unclip actuator rod for vehicle level sender at bottom transverse link -arrow-.

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

–  First remove front subframe bolts -2- and -3- (left and right). Then unscrew bolts -1-.   Note To avoid having to check and adjust wheel alignment, only loosen the front subframe mountings and lower the subframe at the front. –  Lower subframe at the front.

–  Unplug electrical connector at oil pressure switch -F1--arrow-.

–  If fitted, unscrew bolts -1- and detach continued coolant circulation pump -V51--item 2- from upper section of sump.   Note Coolant hose to cylinder block does not have to be disconnected.

–  Detach wiring at alternator. –  Unscrew bolts -arrows- and remove alternator.   Note t  If alternator sticks in its bracket, screw bolt back in again down to the last 2 turns. t  Tap carefully on bolt heads with flat side of hammer to release threaded bushes of alternator mountings.

–  Unbolt heat shield -1- for drive shaft (right-side) if necessary.

–  Detach electrical wiring -1- and -2- at starter.   Note Do not disconnect earth cable -3-.

–  Pull heat shield -1- off solenoid switch. –  Remove bolts -2- and -3- and detach starter.

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

–  Place used oil collection and extraction unit -V.A.G 1782- under engine, because oil will drain out again. –  Unbolt sump (bottom section) -1- and remove it carefully. –  Remove oil pump → Chapter.

–  Lift engine slightly with spindle of support bracket -10-222 A-.   Note Make sure that air duct at rear of intake manifold is not damaged when lifting engine.

–  Unbolt bracket for noise insulation -arrows-.

–  Unscrew engine/gearbox securing bolts in area of sump (top section). –  Check whether a 10 mm socket (e.g. 3220) can be inserted through access hole -arrows-. Widen out access hole if necessary.

–  Unscrew bolts -1- and -2- for sump (top section). –  Press sump (top section) off spring pins on cylinder block. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals and O-rings. t  Fit all cable ties in the original positions when installing. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.

–  Remove sealant residue from sump (top section) and cylinder block 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 (nozzle approx. 1 mm Ø).

–  Apply sealant bead to clean sealing surface of top section of sump, as shown in illustration. l  The bead of sealant should be approx. 1.5 mm wide.   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  Apply sealant with particular care around hole -arrow- in cylinder block. t  The sump (top section) must be installed within 5 minutes after applying sealant. –  Fit sump (top section) and tighten all bolts securing sump (top section) to cylinder block initially to 5 Nm in diagonal sequence. –  Tighten bolts for sump (top section) / gearbox to 45 Nm.

–  Tighten bolts -1- to 16 Nm and bolts -2- to 22 Nm in a diagonal sequence. –  Install oil pump → Chapter. –  Install sump (bottom section) → Anchor. –  Renew O-ring on guide tube for oil dipstick and insert guide tube into hole in top section of sump. –  Install starter → Rep. Gr.27. –  Install alternator → Rep. Gr.27. –  Install subframe → Rep. Gr.40. –  Install air conditioner compressor → Rep. Gr.87. –  Install poly V-belt → Chapter. –  Install lock carrier with attachments → Rep. Gr.50. –  Install bumper cover (front) → Rep. Gr.63. –  Fill up with engine oil and check oil level → Chapter. –  Observe notes on procedures required after connecting battery → Rep. Gr.27. –  Fill cooling system → Anchor. Tightening torques

Component		Nm
Sump (top section) to cylinder block and sealing flanges	M7	16
	M8	22
Sump (top section) to gearbox		45
Bracket for noise insulation to subframe		10
Continued coolant circulation pump -V51- to sump (top section)		10
Engine mounting to subframe		23
Reservoir bracket to body		10
Refrigerant line bracket to sump		10
Secondary air pump bracket to longitudinal member		10
Oil cooler to sump (top section)		30
Guide tube for oil dipstick to secondary air pipe		10