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 t  Sealant → Electronic parts catalogue Removing l  Engine removed and secured to engine and gearbox support → Chapter l  Engine oil drained → Booklet811, → Booklet812 or → Booklet818. –  Remove drive plate → Chapter. –  Remove timing chain covers: left-side → Chapter, right-side → Chapter, bottom → Chapter. –  Remove chain for auxiliary drives → Chapter. –  Remove sealing flange (pulley end) → Chapter.

–  Remove air conditioner compressor → Rep. gr.87. –  Remove sump (bottom section) → Chapter. –  Remove oil pump → Chapter.

–  Remove bolts -2- and -4- and detach coolant pipe (left-side) from subframe.   Note Disregard items marked -1, 3- and -arrows-. –  Removing idler roller for poly V-belt → Chapter.

–  Remove bolts -1- and -2- and detach guide tube for oil dipstick.

–  Remove bolts -1 ... 4- for sump (top section). –  Press sump (top section) off dowel pins on cylinder block. Installing   Note Renew gaskets, seals and O-rings.   Caution Protect lubrication system against contamination. Cover exposed parts of the engine.

WARNING Protect eyes against injuries. Wear safety goggles. –  Remove remaining sealant from sump (top section) and cylinder block using 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 nozzle of tube at front marking (nozzle Ø approx. 1.5 mm).

–  Fit seals -1- and -2- in sump (top section).   Caution Make sure lubrication system is not clogged by excess sealant. The sealant bead must not be thicker than specified. –  Apply beads of sealant -arrows- onto clean sealing surface of sump (top section) as shown in illustration. l  The grooves on the sealing surfaces must be completely filled with sealant. l  The beads of sealant must project 1.5 … 2.0 mm above the sealing surface.   Note The sump (top section) must be installed within 5 minutes after applying the sealant.

–  Fit sump (top section) and tighten bolts → Fig.. Remaining installation steps are carried out in reverse sequence; note the following: –  Install idler roller for poly V-belt → Chapter. –  Install coolant pipe (left-side) → Chapter. –  Install oil pump → Chapter. –  Install sump (bottom section) → Chapter. –  Install air conditioner compressor → Rep. gr.87. –  Install sealing flange (pulley end) → Chapter. –  Install chain for auxiliary drives → Chapter. –  Install timing chain covers: left-side → Chapter, right-side → Chapter, bottom → Chapter. –  Install drive plate → Chapter.