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 crane -VAS 6100- or workshop crane -V.A.G 1202 A-

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. –  Lift off engine cover -arrows-.

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

–  Disengage solenoid valve 1 for activated charcoal filter system -N80--item 1- at air duct. –  Unscrew 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.

–  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 eyelets 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-fasteners -1- and -2- and take off front noise insulation. –  If fitted, release quick 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. –  Unplug electrical connector -arrow- at oil level/oil temperature sender -G266-.

–  Unbolt refrigerant pipe bracket from sump -arrow-.

–  Unplug electrical connector -1- for magnetic clutch on air conditioner compressor.   WARNING 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 there is clearance for exhaust system.

–  Unscrew bolt -arrow- at support for intake manifold (top section).

–  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 position 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 (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  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.  Tighten bolts -1 ... 18- in diagonal sequence initially to 5 Nm. 2.  Tighten bolts securing sump to gearbox to 45 Nm. 3.  Tighten bolts M10 -arrows- to 40 Nm. 4.  Tighten bolts -1 ... 18- in diagonal sequence to 15 Nm.   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