Audi Workshop Service and Repair Manuals

Removing and installing sump (bottom section) Special tools and workshop equipment required

t  Used oil collection and extraction unit -V.A.G 1782- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Electronic parts catalogue

Removing –  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. Leave rear noise insulation in position.

–  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Drain off engine oil. –  Unscrew bolts -arrows- and detach oil cooler with coolant hoses -1- and -2- attached.   Note

To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Unbolt retainer for refrigerant pipe (right-side) from sump -arrow-.

–  Unbolt anti-roll bar mountings (left and right) -1- and -2-. –  Pivot anti-roll bar downwards.

–  Unplug electrical connector -1- at oil level and oil temperature sender -G266--arrow- and move wiring clear. –  Remove bolts for sump (bottom section) -2-. –  Release sump (bottom section) from bonded joint, taking care not to bend sump (sheet-metal version). Installing   Note t  Renew seals and gaskets. t  On the sheet-metal version, the sump (bottom section) must be renewed if its coating is damaged or if it is bent.

WARNING Wear safety goggles. –  Remove remaining sealant on bottom and top section of sump with a rotating plastic brush or similar.   Note On the sheet-metal version, take care not to damage the coating on the sump (bottom section). –  Clean sealing surfaces; they must be free of oil and grease.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 1 mm).

–  Apply bead of sealant -arrow- onto clean sealing surface of sump (bottom section) as illustrated. l  The bead of sealant should be approx. 1.5 mm wide.   Note t  The bead of sealant must not be thicker than specified, otherwise excess sealant can enter the sump (bottom section) and obstruct the strainer in the oil intake pipe. t  The sump (bottom section) must be installed within 5 minutes after applying sealant. –  Fit sump (bottom section) and tighten all bolts initially to 5 Nm in diagonal sequence. –  Tighten bolts on sump (bottom section) in diagonal sequence –  Install oil cooler → Chapter. –  Install anti-roll bar → Rep. Gr.40. –  Fill up with engine oil and check oil level → Booklet803 or → Booklet805. Tightening torques

Component	Nm
Oil cooler to sump (top section)	9
Sump (bottom section), aluminium version to sump (top section)	9 1)
Sump (bottom section), sheet-metal version to sump (top section)	5 + 90° 1)2)3)
Bracket to sump	9
Oil drain plug	30
l  1) Tighten in diagonal sequence. l  2) Renew bolts. l  3) 90° = one quarter turn.