Removing and installing upper section of sump — AUDI

AZB
Special tools, testers and equipment required

Engine support bracket 10-222A with adapter 10-222A/3
Drip tray V.A.G 1306
Electric drill with plastic brush attachment
Torque wrench 10 Nm/ 45 Nm

Obtain radio code on vehicles with coded radio.
With ignition switched off, disconnect battery earth strap.
Pull out dipstick.

Unbolt dipstick guide tube at front of cylinder head (right side), and pull out of sump from the top.
Remove noise insulation panel -arrows-.
Remove bumper

=> General body repairs, Exterior; Repair group 63; Front bumper; Removing and installing front bumper - Assembly overview
General body repairs, Exterior
Front bumper
Removing and installing front bumper - Assembly overview

Move lock carrier to service position

=> General body repairs, Exterior; Repair Group 50; Front body; Lock carrier service position

Warning
Hot steam can escape from the expansion tank when the filler cap is opened. Cover the filler cap with a cloth and unscrew it carefully.
Unscrew cap on coolant expansion tank.
Place drip tray V.A.G 1306 below engine.
Turn drain screw -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection.

Also open coolant drain screw -arrow- at rear right of sump.
Draining off and filling up coolant =>Page
19-19
.
Drain off engine oil.

Use a separate container to collect the engine oil.

Set up support bracket 10-222A with adapter 10-222A/3 on bolted flanges for wing panels.
Attach support bracket to front and rear lifting eyes on engine.
Raise engine as far as possible with spindles of support bracket.

Cut open cable ties -arrows-, open retainer for starter cable and take out cable.
Unbolt torque reaction support at front of sump.
Unbolt coolant pipe from sump.
Unplug connector from oil pressure switch on left of sump.

Remove torque reaction support -1-.
Release hose clamps -arrows-.
Remove water pipe -2-.

Place drip tray V.A.G 1306 under engine.
Remove oil filter.
Release hose clamps -arrows-.
Remove oil cooler -1-.

Unscrew bottom nuts on engine mountings -1- (left and right sides).
Mark positions of securing points -1- and locating sleeves -2- under engine mountings on left and right sides.

First remove front subframe bolts -2- and -3- (left and right). Then unscrew bolts -4-.
Move anti-roll bar downwards.

Remove charge air cooler -2- on right side (release hose connection at top and 3 rubber mountings).

Remove air duct from connector elbow on alternator -3-.
Disconnect wire from terminal 30/B+ -1-.
Tightening torque: 16 Nm
Disconnect wire from terminal D+ -2-.
Tightening torque: 4 Nm

Remove hexagon socket head bolt -1-
-lock nut -2-
Tightening torque: 45 Nm
Slacken bolt -3-.
Tightening torque: 22 Nm
Take out alternator -4- from below.

1 -
Remove air pipe -1-.
2 -
Mounting for oil and air conditioner pipes
3 -
Mounting on cylinder block
4 -
Release hose clamp

Disconnect wire from terminal 30/B+ -1-.
Tightening torque: 16 Nm
Unplug connector for terminal 50 -2-.

Remove right wheel

Unscrew top bolt -1- from right wheel housing.
Tightening torque: 65 Nm
Unscrew lower bolt (accessible from engine side).
Tightening torque: 65 Nm
Remove starter from the front of vehicle.

Note:

To avoid having to check and adjust wheel alignment, only loosen the front subframe mountings and lower the subframe at the front.

Remove lower section of sump.
Detach return pipes for turbocharger from upper section of sump.

Unbolt cover plate -2- for oil pump sprocket.

Notes:

When loosening bolt -2- securing cover plate, counter-hold at welded nut.
When installing, make sure that the plate engages in position -arrows-.

Unbolt the two oil supply pipes, and pull the longer of the two pipes downwards to detach from upper section of sump.

Unbolt oil pump from engine so that the shorter oil supply pipe can be detached (do not remove oil pump).
Unscrew bolts securing upper section of sump to gearbox.
Unbolt upper section of sump from engine.

Note:

Two M6 bolts and two M8 bolts are located vertically at rear of sump upper section (in front of joint between engine and gearbox).

Installing:

Install in the opposite order to removing. When installing, note the following points:

Clean the sealing surfaces; ensure that they are free of oil and grease.

Warning
Wear protective goggles.
Remove any residues of sealant on sump and engine block using plastic brush attachment, or similar.

Note:

The sump must be installed within 5 minutes after applying silicone sealant.

Sealant

=> Parts Catalogue

Cut off nozzle of tube at front marking (diameter of nozzle approx. 3 mm).
Thickness of sealant bead: 2 ... 3 mm

Note:

The bead of sealant must not be thicker than 3 mm, as otherwise excess sealant may enter the sump and block the strainer in the oil intake pipe.

Make sure sealing surface is clean and then apply silicone sealant on sealing surface of sump, as shown in illustration. (Illustration shows position of sealant on cylinder block.)

Note:

Be particularly careful when applying the sealant around the rear sealing flange -arrows in illustration-.

Locate sump in position immediately, and tighten all bolts securing sump to cylinder block to 5 Nm initially.
Tighten bolts securing sump to gearbox to 45 Nm.
Tighten bolts securing sump to cylinder block in diagonal sequence in 2 stages; tighten to 10 Nm when tightening second time.
Tighten M10 bolts securing sump to cylinder block to 45 Nm.

Clean both sealing surfaces for lower section of sump; ensure that they are free of oil and grease.
Fit new gasket on lower section of sump and install on upper section of sump with two diagonally opposite bolts.
Tighten all securing bolts hand-tight.
Tighten bolts to 10 Nm with torque wrench, working from the centre outwards.
Fit new seal on oil drain plug and tighten to 30 Nm.

Notes:

When installing the upper section of the sump with the engine removed from the vehicle, ensure that the sump is positioned flush with the cylinder block at the flywheel end.
The sealant must be left to dry for about 30 minutes after installing the sump before engine oil can be put in.

Fill up coolant =>Page
19-19
.
Fill up engine oil.

Oil system capacity:

=> Maintenance manual

Install subframe

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 40; Removing and installing subframe
Running gear, Front-wheel drive and four-wheel drive
Removing and installing subframe

Install lock carrier in normal position

=> General body repairs, Exterior; Repair Group 50; Body front; Lock carrier service position

Install bumper

=> General body repairs, Exterior; Repair group 63; Front bumper; Removing and installing front bumper - Assembly overview
General body repairs, Exterior
Front bumper
Removing and installing front bumper - Assembly overview

Install noise insulation.

Tightening torques

Component · Nm
Upper section of sump to cylinder block · M6 · 10
M8 · 20
Lower section of sump to upper section of sump · 10
Sump to gearbox · M8 · 25
M10 · 45
Coolant pipe to sump · 10
Oil drain plug in lower section of sump · 30
Dipstick guide tube to cylinder head · 25
Oil pump to cylinder block · 25
Oil pump supply pipes to upper section of sump · 10
Front sealing flange · M6 · 10
Collar bolt · M8 · 30
Bracket for coolant pipes to sump · 10
Coolant drain screw on engine · 20

Component · Nm
Stop for torque reaction support to bracket on engine · / 25
Engine mounting to subframe · 25
Torque reaction support to front of sump · 25
Engine mounting to engine support · 25
Chain sprocket to oil pump · 25

Other tightening torques

Nut for engine mounting -1- · 25
Bolts -2- and -3- · 60
Combi bolt -4- ** · 110 + 90°

** Combi bolt -4- must be replaced after removing.