Audi Workshop Service and Repair Manuals

Removing sump (top section)

Special tools and workshop equipment required

t	Support bracket -10-222 A- and adapter -10-222 A/4-

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

t	Retainer -3180-

t	Workshop hoist -VAS 6100- or -V.A.G 1202 A-

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  Locking pin -3204- t  TORX wrench T45

Procedure   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  Detach rubber seal from plenum chamber cover in direction of -arrow-. –  Detach plenum chamber cover -1- towards the front.

–  With ignition switched off, disconnect battery earth cable -arrow-.

–  Remove engine cover panel -arrows-.

–  Detach cover -2- from air cleaner. –  Unbolt air duct -1- for air cleaner at lock carrier and lift out.

–  On vehicles with secondary air system, turn connecting pipe through 45° to the right -arrow- and detach from air cleaner housing.

–  Remove air intake hose between air mass meter -G70- and air intake elbow. –  Unplug electrical connector at solenoid valve 1 for activated charcoal filter system -N80- and detach solenoid valve from bracket. –  Detach electrical connector at air mass meter -G70-. –  Unscrew and remove air cleaner housing.

–  On vehicles with secondary air system, disconnect hose -arrow- from secondary air connecting pipe.

Tensioning roller with hexagon flats:   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- using a 17 mm ring spanner to slacken the poly V-belt. –  Lock tensioner in position by inserting locking pin -3204- in locating holes -arrows-. –  Guide poly V-belt over viscous fan and detach belt.

Tensioning roller with hexagon socket:   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- using a 10 mm hexagon key to slacken the poly V-belt. –  Lock tensioner in position by inserting locking pin -3204- in locating holes -arrow 1- and -arrow 2-. –  Guide poly V-belt over viscous fan and detach belt.

Vehicles with throttle cable and cruise control system: –  Detach vacuum hose -2- at vacuum unit for cruise control. –  Unscrew bolts -1- and move vacuum unit downwards.

All models: –  Set up support bracket -10-222 A- with adapter -10-222 A/3- on wing panel flanges. –  Connect support bracket to front and rear lifting eyes on engine. –  Raise engine as far as possible with spindles of support bracket.

–  Unbolt dipstick guide tube on cylinder head -arrow- and lift out upwards.

–  Remove noise insulation -arrows-. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Drain off engine oil. –  Remove front bumper → Rep. Gr.63. –  Move lock carrier to service position → Rep. Gr.50.   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully.

–  Open filler cap on coolant expansion tank. –  Place drip tray for workshop hoist -VAS 6208- under engine. –  Turn drain plug -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection.

–  Also open coolant drain plug on engine -arrow-. –  Drain off coolant.

Vehicles with automatic gearbox: –  Remove bracket for ATF pipes -arrows-.

All models: –  If fitted, unplug electrical connector -arrow- at oil level/temperature sender -G266- and move wiring clear.

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

–  Cut through cable ties -arrows-. Open retainer for starter wiring and take out wiring. –  Unbolt torque reaction support and stop for torque reaction support.

–  Clamp off both coolant hoses leading to oil cooler with hose clamps -3094-. –  Place drip tray for workshop hoist -VAS 6208- under engine. –  Unscrew coolant pipe -arrows- and detach it from hoses. –  Unplug connector at oil pressure switch -F1- and move wiring clear.

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

–  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. –  Pivot anti-roll bar downwards.

–  Detach wires -1- and -2- at starter and detach insulator at positive connection of starter. –  Remove starter bolts -arrows- from gearbox side. –  Unscrew clamp on right of top section of sump and move electrical wiring clear. –  Remove starter.

–  Remove sump (bottom section) -1-.

Vehicles with “engine generation II”: –  Unscrew cover plate -1-. –  Remove gasket -2-.

Vehicles with “engine generation III”: –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Unbolt brackets -arrows- and pull off long oil supply pipe from below.

–  Unscrew chain sprocket using TORX wrench T45 -arrow- and pull it off oil pump.

–  Remove oil pump together with short oil supply pipe -arrows-.

All models: –  Unscrew engine/gearbox securing bolts in area of sump (top section). –  Unscrew bolts -1- for sump (top section). –  Press sump (top section) off spring pins on cylinder block. –  Remove sump (top section).