Audi Workshop Service and Repair Manuals

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

t  Used oil collection and extraction unit -V.A.G 1782- t  Safety goggles t  Electric drill with plastic brush attachment t  Sealant → Electronic parts catalogue Removing l  Engine separated from gearbox → Chapter, engine secured to engine and gearbox support → Chapter. –  Remove clutch pressure plate → Rep. Gr.30. –  Remove dual-mass flywheel → Chapter. –  Remove timing chain covers (left and right) → Chapter. –  Remove intake manifold → Rep. Gr.24. –  Remove oil filter housing → Chapter. –  Remove timing chain cover (bottom) → Chapter.   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. –  To slacken poly V-belt, pivot belt tensioner in direction of -arrow- (use a socket wrench with 3/8” drive).   Note t  Make sure that the head of the socket wrench is long enough to engage fully in the belt tensioner. t  “Stahlwille 425QR” or similar can be used. –  Remove poly V-belt. –  Release pressure from the tensioner.

–  Remove bolts -arrows-. –  Remove poly V-belt tensioner from top section of sump.

–  Detach coolant hose -1- from alternator. –  Unplug electrical connector -5-. –  Unscrew bolt -4- and remove heat shield.   Note Make sure that the coolant pipes remain in position, otherwise O-rings must be renewed; re-attach bracket -3- after removing heat shield if necessary. –  Unscrew electrical wire -2- from alternator.

–  Remove bolts -arrows-.   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. –  Remove alternator.

–  Remove bolts -arrows-. –  Remove bracket for alternator.

–  Remove bolts -arrows-. –  Detach front coolant pipe from engine and coolant pump.

–  Unplug electrical connector -2- at oil level and oil temperature sender -G266-. –  Position used oil collection and extraction unit -V.A.G 1782- below engine. –  Unbolt sump (bottom section) -1- and carefully release it from bonded joint.

–  Remove oil pump → Chapter. –  Remove bolts -1 … 7- for sump (top section). –  Carefully release sump (top section) from bonded joint and pry sump off dowel pins on cylinder block.

Installing   Note Renew seals and O-rings.   WARNING Wear safety goggles. –  Remove sealant residue from sump (top section) and cylinder block with rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease.   Note

Note the use-by date of the sealant. –  Cut off tube nozzle at front marking (nozzle approx. 2 mm Ø).

–  Insert new seals -1 ... 4- in grooves on retaining frame.

–  Apply beads of sealant -1- and -2- onto clean sealing surface of sump (top section) as illustrated. l  Width of sealant beads: 2.5 mm.   Note t  The bead of sealant must not be thicker than specified, otherwise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe. t  The sump (top section) must be installed within 5 minutes after applying sealant.

–  Fit sump (top section), paying attention to dowel sleeves → Fig., and tighten bolts -1 ... 7- in diagonal sequence initially to 5 Nm. –  Tighten bolts -1 ... 7- in diagonal sequence. Remaining installation steps are carried out in reverse sequence; note the following: –  Install oil pump → Chapter. –  Install coolant pump → Chapter. –  Install sump (bottom section) → Anchor. –  Install coolant pipe (front) → Chapter. –  Install alternator → Rep. Gr.27. –  Install timing chain cover (bottom) → Chapter. –  Install crankshaft oil seal (gearbox end) → Chapter. –  Install oil filter housing → Chapter. –  Install intake manifold → Rep. Gr.24. –  Install timing chain covers (left and right) → Chapter. –  Install dual-mass flywheel → Chapter. –  Install clutch pressure plate → Rep. Gr.30. Tightening torques

Component	Nm
Sump (top section) to retaining frame	14
Bracket for alternator to cylinder block	22
Tensioner to sump (top section)	9