Removing and installing upper part of sump - engine generations I and II — AUDI

ABC ACZ
Special tools and workshop equipment required

Hose clamps 3094

V.A.G 1306
Drip tray

Removing

Heed (if necessary obtain) radio code for vehicles with encoded radio.
Disconnect battery earth strap with ignition switched off.
Pull out dipstick.
Remove lower part of sump => Page
17-19
.

Screw out front bolts -arrows- of subframe.

Attention:
Slackening off the bolts lowers the subframe by approx. 100 mm.
Note:

To avoid the need for wheel alignment, subframe is only to be unfastened/lowered at front.

Unscrew torque reaction support -1-and its stop -2-.

Pinch off coolant hoses to oil cooler and coolant pipe with 3 hose clamps 3094.

Unscrew pipe holders for air conditioner and coolant pipe at front of sump -arrows-.

Attention:
Refrigerant circuit of air conditioner is never to be opened.

Pull hoses -1- and -2- off oil cooler -4-.

Note:

If same upper part of sump is to be re-used, oil filter and oil cooler need not be removed. Otherwise:

Place drip tray in position.
Remove oil filter -3-.
Remove oil cooler.

Unscrew starter retaining bolts/nut -arrows- from gearbox side.
Screw in upper bolt again by approx. 2 turns and leave starter hanging from engine block.

Note:

Leave wires -1- and -2- connected to starter and leave alternator in position.

Pull off wires -1...3-.

Screw out engine/gearbox connecting bolts in area of upper part of sump.

Vehicles with engine generation I:

Unscrew suction pipe for oil pump -arrows-.

All models:

Screw out bolts -1- for upper part of sump.
Press upper part of sump off spring pins of cylinder block.
Detach upper part of sump.

Installing

Install in reverse order, paying attention to the following:

Note:

Always replace self-locking nuts, gaskets and sealing rings.

Clean sealing surfaces before installing upper part of sump.
Replace O-ring of guide tube for dipstick.

Vehicles with engine generation I:

Coat bolts -1- with locking fluid D 000 600 A2 and fit.

All models:

Fit upper part of sump and pre-tighten bolts -1- and -2- for upper part of sump/cylinder block diagonally to 5 Nm.
Check correct positioning of guide tube for dipstick in upper part of sump.

Tighten bolts for upper part of sump/gearbox.
Tightening torque for M8 bolts: 25 Nm
Tightening torque for M10 bolts: 45 Nm

Finish-tighten bolts for upper part of sump/cylinder block diagonally to 10 Nm.
Fit lower part of sump => Page
17-21
.
Fit subframe with new bolts.

=> Running Gear, FWD; Repair Group 40; Removing and installing subframe
Running Gear, FWD
Removing and installing subframe

Allow stop for torque reaction support to settle on rubber buffer for torque reaction support and tighten bolts to 40 Nm.
Pour in engine oil and check oil level.
Fill with coolant=> Page
19-7
.
After connecting battery, enter radio anti-theft code.

=> Radio operating instructions

Set clock to correct time.

Tightening torques

Component · Nm
Upper part of sump to cylinder block · 10
Upper part of sump to gearbox · M8 · 25
M10 · 45
Oil cooler to upper part of sump · 30
Suction pipe to oil pump · 10
Torque reaction support to upper / part of sump · / 42
Stop for torque reaction support / to body · / 40
Starter to engine/gearbox · M10 · 45
M12 · 65