S3 Sump Removal and Refit (with pics)

[Welly]

Hi, I've gone to do this job today, drained the oil removed the filter, removed the three bigger bolts, removed around half of the smaller bolts, then came to one that was very tight to undo, kept working the bolt backwards and forwards then the bolt went solid and the head has rounded off, the bolt is probably 5mm off the sump but now I can't tighten it or slacken it, has anybody encountered this or can anyone think of a way of removing it thanks

Thats a bit of a pain. You should be able to get a hex/allen key into the inner bit to get turn on it, but it's odd that it's got stuck halfway out.

If you can't get it out, then you could use a dremel cut the head off, the use a grip wrench to wind the remainder out?

 

[Pabl0]

Are they the only bolts holding the sump on now? As the weight of the sump could be hindering you getting them undone..? I would have started with the hardest ones first as they are a *****!

 

[dusty]

I've tried with an Allen key and its done the same and rounded off, I did undo the most awkward ones to get at first, there is no weight on the bolt, all I can think is the sump has been off before and the bolt has been cross threaded when put back in, I've had to admitt defeat for today I've put everything back together put a new filter on and new oil in, looks like I'm going to have to cut the bolt head off as welly suggested I'm just a bit concerned about getting the rest of the bolt out afterwards

 

[danger S3]

you could try Irwin Bolt Extractors Bolt Extractors - Screw & Bolt Extractors - Tools - IRWIN TOOLS

I've used them quite successfully on many a troublesome bolt, got the set for one particular job and have used them quite a few times since. they do trash the bolt but generally if its that rounded you will be replacing it anyway

 

[dusty]

I will get some bolt extractors and give it a go, got nothing to loose, thanks for the suggestions guys

 

[typertony]

If there is 5mm of thread showing, could you cut the head off of the bolt and use a nut when you put it back together?

not a perfect fix, but it might help

 

[TwinCamMan]

It sound like you'll have to drill it and use and Easi Out. Is it one of the bolt that's easily accessible with a drill bit?

 

[dusty]

If I can't undo it with a 3/8" ratchet and socket I don't fancy my chances of drilling it and removing with an easy out, easy outs are very hard and break quite easy, I've ordered a bolt extractor set just waiting on it coming, if that doesn't work then I will drill it out and re tap it, it's one of the bolts at the crank pulley end of the engine so I should get in there with a drill, I've put the car back together for now and she's running fine with no oil leaks

 

[Vex182]

Well I started this after work today and want to do it al tomorrow, got all the parts needed. Getting to the 10mm bolts are no problem, the 16mm near the power steering pipe is seized solid! Also that pipe does not move out the way! Any advice please? The bolt is very slightly rounded off too. Not a good start!

 

[Vex182]

Anyone please?

 

[danger S3]

if i remember correctly there was a wee bracket holding the power steering pipe to the block, although mine just fell off :S
after that fell off it moved out of the way enough, had to be kinda rough with it though to get it out the way.
hope that helps

 

[dusty]

I used a 1/2" breaker bar and 6 point socket to crack the bolts off and then undid them with a spanner, 6 point socket will grip the bolt better if its slightly rounded off, you could also try warming the bolt head with a small gas torch this might help also

 

[Vex182]

Thanks for the advice. I had already removed the bracket for the pas. In the end I got a good 5/8" socket it on as the fitted better than a 16mm in the end. The pickup was really clean anyway but all has been replaced and looks like no leaks after 25 miles of driving. Car has done 104k. Was on long life up to 80k and then oil changed at 90k then 95k and then 100k.

 

[Paradox1]

Having nightmare with those difficult bolts. I got every bolt out with little effor but there is one thats at an angle, cant get a socket to sit properly on the head, the allen keeps slipping.

The show must go on!

 

[Sam_]

1/4 ratchet with a wobble extension was a godsend when doing this. Trip to Halfords?

 

[Paradox1]

Its not happening mate. the garage who did my oil pick up last year obviously rounded the allen part of the bolt and decided to put it back in there. so annoyed. Ive been trying all day but to no avail. will see how things go next weekend then

 

[Arnie013]

Just back from Belfast Audi to pick up the parts i ordered for this. Prices are as follows.
Suction pipe (06A115251) 9.18
O-Ring 3.75
Sealant 17.90
They ordered in 06B115251 which is too short, correct part should be in tomorrow, so hopefully by the weekend this should be done.
Just wish i had a pit or a 4 poster!

 

[Paradox1]

Take out those 3 bolts next to the gearbox first.

you dont want to be like be getting all the other bolts out but one lol

 

[JD09]

Brief bump for this guys. Intending on doing this this weekend.

Could I just check that the stuff I need is as follows;

5l oil
Oil filter
New pickup pipe
Sealant

Anything else?

 

[Wallm0nkey]

Get an O ring for the pickup too!

 

[JD09]

Get an O ring for the pickup too!

Ah yes, missed that off, cheers pal.

 

[JD09]

Quick bump, the part number on the first page for the OPP is incorrect by one digit. It should be 06A-115-251. Otherwise you'll end up with a very short, B5 A4 unit... like the one sat on my desk currently

 

[<tuffty/>]

Quick bump, the part number on the first page for the OPP is incorrect by one digit. It should be 06A-115-251. Otherwise you'll end up with a very short, B5 A4 unit... like the one sat on my desk currently

Have edited the part number references to reflect this

<tuffty/>

 

[JD09]

Thanks Paul. Good news from my end - local dealership to my house have one left in stock (only one in London without ordering lol) so can still DIY it tomorrow.

 

[JD09]

Have edited the part number references to reflect this

<tuffty/>

Paul, sorry to be a PITA - do you recommend using an engine flush while doing all this? I've got all the above, new oil pickup pipe, o ring, will clean the sump, new oil... seems madness to miss out a stage if you guys recommend it!

Cheers as per.

 

[JD09]

Bump, anyone? Can pop by ECP or halfords if it's worth doing.

 

[Sam_]

I've used one in the past and on previous engines. Didn't do any harm.

 

[kevlibstt]

hi, started to remove the sump today ,3 big bolts ,return pipe , oil sensor ,19 small bolts , and 1 which will not move and to top it all i think i have rounded it off so how can i get this out thanks kev

 

[<tuffty/>]

hi, started to remove the sump today ,3 big bolts ,return pipe , oil sensor ,19 small bolts , and 1 which will not move and to top it all i think i have rounded it off so how can i get this out thanks kev

you can use a 5mm allen key on the inside of the bolt...

You could also try something like this...
http://www.amazon.co.uk/Irwin-Bolt-Grip-Remover-Expansion/dp/B000QW6K8I

Depends where the bolt is I guess...

<tuffty/>

 

[Wallm0nkey]

The bolt head and Allen key rounded off? Maybe give an Irwin bolt extractor a bash. I had the a problem at the end nipping them back up with the torque wrench one snapped off... Finished it off by feel to save any more it appears leak free so I'll wait for the weather to pick up and drop it again. Just hope it comes out I normally use new bolts but decided not to for some reason!

 

[JD09]

Thanks again for this thread!

View attachment 26010

View attachment 26011

New oil, filter, oil pickup pipe and cleaned the sump.

 

[kevlibstt]

hi big thanks to tuffty/wallm0nkey bought the irwin bolt remover, out in seconds .today i got 20 new bolts from tps 10.80 bargin . i cleaned the oil filter thingy was slightley clogged up ,but did find in the sump a very small plastic bag .will be putting it all back together at the weekend . then find a fmic and tip any suggestions and a great big thanks for the original post and pics

 

[Wallm0nkey]

I'm hoping to do tip and front mounted intercooler in the next few months and from research the Badger5 tip is the one to have! Fmic I fancy the Wagner one purely based on the fact it looks pretty stealthy and retains the fogs. Someone on here had one and it just looked well put together and easy to fit I'm not sure how it fares performance wise against others but I'm not aiming for silly power as of yet so figure it will be better then the side mounts. The welly cooler seems well regarded though for the price of it.

 

[willh92]

What torque settings are required for these bolts? Obviously the three bigger bolts will be set to a higher torque as well?

 

[<tuffty/>]

Paul, sorry to be a PITA - do you recommend using an engine flush while doing all this? I've got all the above, new oil pickup pipe, o ring, will clean the sump, new oil... seems madness to miss out a stage if you guys recommend it!

Cheers as per.

Sorry dude... didn't notice this one...

Not a massive fan of engine flush tbh... its a personal thing, just not keen on the idea of it... never used it personally either so couldn't base my dislike on experience either... just something that never appealed..

<tuffty/>

 

[JD09]

Don't worry chap, decided against it. Either you or someone else said in another thread "would you be happy with putting something around your engine, rather than oil that's been in it for 90k+". Fair point!

 

[<tuffty/>]

Don't worry chap, decided against it. Either you or someone else said in another thread "would you be happy with putting something around your engine, rather than oil that's been in it for 90k+". Fair point!

Exactly...

<tuffty/>

 

[lol4fun]

ive always been told never to use engine flush in petrol turbo engines and seen a bmw 320d over run(run off its own oil with no control or limit to the revs) when an engine flush was used.

i had the sump off my car at the weekend and have a good 80% left of the sealant, anyone need some?

 

[Jenno007]

Tried removing my sump today, got all the bolts out but the sealant is working as a glue to hold it in place.

Any suggestions how to easily remove the sump without damaging it?

 

[willh92]

Try running a Stanley knife round the join?