Sump Removal

[Pauls898]

Can I remove the sump from my 3.0L TDI with the engine in the car? I know I have to remove the splash guard but can the sump be removed easily? I reason I need to remove it is there's a rust bubble in the corner and I'm worried if this rusts anymore the oil will all leak out! See photo attached. I'm thinking whether a local workshop could grind and weld this up or do I need to source a replacement sump cover?36389

[Pauls898]

Can I have a reply on this one as I need to do a service but I need to sort out this problem? Thanks.

[Pauls898]

Can I have your advice please?

[Jinxit]

Hi,

I can’t answer you question because I don’t know the answer but you may want to ask at your local dealer. In my experience they are normally happy to offer advice.

[VAG-Abound]

Is there any warranty left on the car? If so get it looked under that.

If not it doesn't look to be very deep. Wire brush on a drill plus a dab of Hammerite would probably stabilise it.

[arman123]

Removing and installing sump (bottom section)




Special tools and workshop equipment required




t
Electric drill with plastic brush




t
Safety goggles




t
Sealant → Electronic parts catalogue (https://ctrl:ext-dok=idp40000/)




Removing




–
Draining engine oil, filling up with engine oil and checking oil level → Booklet811 (https://ctrl:ext-igg=idp41376/), → Booklet812 (https://ctrl:ext-igg=idp42400/) or → Booklet818 (https://ctrl:ext-igg=idp43424/).











–
Remove nuts -arrows- and lower anti-roll bar.




https://workshop-manuals.com/audi/a4_mk3/images/a4-4876.png






–
Unplug electrical connector at oil level and oil temperature sender -G266--item 1-.




–
Remove bolts and pry off sump (bottom section) -arrow- carefully.




https://workshop-manuals.com/audi/a4_mk3/images/a4-4877.png






Installing




https://workshop-manuals.com/audi/css/images/Vorsicht.jpg Caution


Protect lubrication system and bearings against contamination.




Cover exposed parts of the engine.







https://workshop-manuals.com/audi/a4_mk3/images/a4-4878.png











https://workshop-manuals.com/audi/css/images/achtung.jpg WARNING


Protect eyes against injuries.




Wear safety goggles.







–
Remove remaining sealant on bottom and top sections of sump with a rotating plastic brush or similar.




–
Clean sealing surfaces; they must be free of oil and grease.


https://workshop-manuals.com/audi/css/images/hinweis.gif Note


https://workshop-manuals.com/audi/a4_mk3/images/a4-4879.png






Note the use-by date of the sealant.




–
Cut off nozzle of tube at front marking (nozzle Ø approx. 1.5 mm).




https://workshop-manuals.com/audi/a4_mk3/images/a4-4880.png











https://workshop-manuals.com/audi/css/images/Vorsicht.jpg Caution


Make sure lubrication system is not clogged by excess sealant.




The bead of sealant must not be thicker than specified.







–
Apply bead of sealant -arrow- onto clean sealing surface of sump (bottom section) as shown in illustration.




l
Width of sealant bead: 2 mm.


https://workshop-manuals.com/audi/css/images/hinweis.gif Note


The sump (bottom section) must be installed within 5 minutes after applying the sealant.




https://workshop-manuals.com/audi/a4_mk3/images/a4-4881.png






–
Fit sump (bottom section) and tighten bolts → Fig. (https://ctrl:IDREF=idp63792/).




–
Install anti-roll bar → Rep. gr.40 (https://ctrl:ext-rl=idp65648/).




–
Install front noise insulation → Rep. gr.66 (https://ctrl:ext-rl=idp66912/).




–
Fill up with engine oil and check oil level → Booklet811 (https://ctrl:ext-igg=idp68240/), → Booklet812 (https://ctrl:ext-igg=idp69264/) or → Booklet818 (https://ctrl:ext-igg=idp70288/).




https://workshop-manuals.com/audi/a4_mk3/images/a4-4877.png



Power unit (http://workshop-manuals.com/audi/a4_mk3/power_unit/fuel_supply_system_diesel_engines/technical_data/safety_precautions/) > 6-cylinder TDI engine (2.7 ltr.; 3.0 ltr. 4-valve common rail), mechanics (http://workshop-manuals.com/audi/a4_mk3/power_unit/6-cylinder_tdi_engine_(2.7_ltr.;_3.0_ltr._4-valve_common_rail)_mechanics/technical_data/engine_number/) > Engine lubrication (http://workshop-manuals.com/audi/a4_mk3/power_unit/6-cylinder_tdi_engine_(2.7_ltr.;_3.0_ltr._4-valve_common_rail)_mechanics/engine_lubrication/oil_pump_and_sump_(bottom_section)/) > Oil pump and sump (bottom section) (http://workshop-manuals.com/audi/a4_mk3/power_unit/6-cylinder_tdi_engine_(2.7_ltr.;_3.0_ltr._4-valve_common_rail)_mechanics/engine_lubrication/oil_pump_and_sump_(bottom_section)/) > Removing and installing sump (