Audi Workshop Service and Repair Manuals

Removing and installing sump (top section) Special tools and workshop equipment required t  Safety goggles t  Electric drill with plastic brush attachment t  Sealant → Electronic parts catalogue

Removing l  Gearbox removed → Rep. gr.34 or → Rep. gr.37. –  Remove timing chain cover (bottom) → Chapter. –  Remove tensioner for poly V-belt → Chapter. –  Remove alternator → Electrical system; Rep. gr.27.

–  Remove bolts -arrows- and detach bracket for alternator. –  Removing oil pump: up to engine number CAU 003 685 → Chapter, from engine number CAU 003 686 onwards → Chapter.

–  Slacken bolts -1 ... 7- for sump (top section) in diagonal sequence and remove. –  Carefully release sump (top section) from bonded joint, pry sump off dowel sleeves and detach. Installing l  Tightening torque → Fig. „„Sump (top section) - tightening torque and sequence““   Note Renew seals and O-rings.   Caution Protect lubrication system and bearings 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 mm).

–  Fit new gaskets -1 … 4- in grooves on retaining frame.

Caution Make sure lubrication system is not clogged by excess sealant. The bead of sealant must not be thicker than specified. –  Apply beads of sealant -1- and -2- onto clean sealing surface of sump (top section) as shown in illustration. l  Width of sealant beads: 2.5 mm.   Note The sump (top section) must be installed within 5 minutes after applying the sealant.

–  Fit sump (bottom section) and tighten bolts → Fig.. Remaining installation steps are carried out in reverse sequence; note the following: –  Installing oil pump: up to engine number CAU 003 685 → Chapter, from engine number CAU 003 686 onwards → Chapter. –  Install bracket for alternator → Chapter. –  Install alternator → Electrical system; Rep. gr.27. –  Install poly V-belt tensioner → Chapter. –  Install timing chain cover (bottom) → Chapter.