Audi Workshop Service and Repair Manuals

Removing and installing sump Special tools and workshop equipment required

t  T-bar and socket, 10 mm -3185-

t  Allen key, long reach -T10058-

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

t  Support bracket -10 - 222 A- Removing

–  Remove engine cover panel -arrows-.

–  Set up support bracket -10 - 222 A- with adapters -10 - 222 A /3- on suspension turrets (left and right) as illustrated. –  Attach spindles -10 - 222 A /11- to engine lifting eyes. –  Partly take up weight of engine with spindles. –  Remove front wheels. –  Remove noise insulation → Rep. gr.66. –  Remove subframe cross brace → Rep. gr.40. –  Remove subframe → Rep. gr.40. –  Place used oil collection and extraction unit -V.A.G 1782- below engine and drain off engine oil.   Note Please observe requirements for disposal. –  Detach connector from oil level and oil temperature sender -G266-. –  Remove bolts securing sump to gearbox.

–  Remove bolts -7-, -8- and -9- from side facing engine. –  Unbolt sump. –  If necessary, loosen sump by striking it lightly with a rubber hammer. –  Remove sealant remaining on crankcase with flat scraper.   WARNING Wear safety goggles.

–  Remove sealant residue on sump with a rotating brush, e.g. an electric drill with a plastic brush attachment. –  Clean surfaces; they must be free of oil and grease. Installing Install in reverse order. Note the following: Tightening torques → Chapter „Sump, oil pump, balance shaft assembly - exploded view“

Securing engine to manual gearbox

Item	Bolt	Nm
1 3)	M10x50 1)	65
2 4)	M12x100 2)	30 + 90°
3 5), 6	M12x75 2)	30 + 90°
4…5 5)	M12x120 2)	30 + 90°
7…9	M10x75 2)	15 + 90°
10	M12x50 2)	30 + 90°
A	Dowel sleeves for centralising
l  1) Steel bolt - is not renewed l  2) Renew bolts. l  3) Also secures starter l  4) Also secures starter, with additional spacer sleeve between starter and gearbox l  5) Also secures cable retainer

Note t  Note the use-by date of the sealant. t  The sump must be installed within 5 minutes after applying the silicone sealant.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 3 mm). –  Apply silicone sealant onto clean sealing surface of sump as illustrated. Sealant bead must: t  be 2...3 mm thick. t  Pass round bolt holes on inside as shown in illustration -arrows-.   Note The bead of sealant must not be thicker than specified, otherwise excess sealant can enter the sump and block the strainer in the oil intake pipe.

–  Apply bead of silicone sealant onto clean sealing surface of sump, as illustrated. (The illustration shows the position of the sealant bead on the crankcase.) –  Immediately fit sump and lightly tighten bolts securing sump to gearbox and all bolts securing sump. The sump must make flush contact with spacer plate/gearbox flange.   Note When installing sump with engine removed from vehicle, ensure that sump is positioned flush with crankcase at flywheel end. –  Tighten sump bolts in diagonal sequence. –  Tighten sump/gearbox bolts.   Note After fitting sump assembly, the sealant must dry for approx. 30 minutes. Then (and only then) fill the engine with engine oil. –  Fill with engine oil and check oil level (Audi A4) → Booklet812. –  Fill with engine oil and check oil level (Audi A5) → Booklet811. –  Install noise insulation → Rep. gr.66. –  Install subframe cross brace → Rep. gr.40. –  Install steering box → Rep. gr.48. –  Install subframe → Rep. gr.40. Further assembly is basically carried out in reverse order of dismantling.