Upper and lower sections of oil pan, removing and installing: Removing

See Caution before beginning repairs on the electrical system  under LUBRICATION SYSTEM COMPONENTS, REMOVING AND INSTALLING .

• With ignition switched off, disconnect battery Ground strap.
• Pull out dipstick.
• Unbolt dipstick guide tube at front of cylinder head (right side), and pull out of oil pan from the top.
• Remove noise insulation panel -arrows-.
  Fig 1: Removing Noise Insulation Panel

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• Remove bumper.

  See FRONT BUMPER .

• Move lock carrier to service position.

  See 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 remove it carefully.
• Remove cap on coolant expansion tank.
• Place drip tray VAG 1306 below engine.
• Turn drain screw -arrow- on radiator counter-clockwise, if necessary install drain hose to connection.
  Fig 2: Locating Drain Screw On Radiator

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• Also open coolant drain screw -arrow- at rear right of oil pan. See COOLING SYSTEM, DRAINING AND FILLING .
Fig 3: Identifying Coolant Drain Screw At Rear Right Of Oil Pan
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• Drain 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.
  Fig 4: Settig Up Support Bracket 10-222A With Adapter 10-222A/3 On Bolted Flanges For Wing Panels

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• Cut open cable ties -arrows-, open retainer for starter cable and take out cable.
  Fig 5: Disconnecting Open Cable Ties

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• Unbolt torque reaction support at front of oil pan.
• Unbolt coolant line from oil pan.
• Disconnect connector from oil pressure switch on left of oil pan.
• Remove torque reaction support -1-.
• Release hose clamps -arrows-.
• Remove water line -2-.
  Fig 6: Removing Torque Reaction Support And Water Line

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• Place drip tray VAG 1306 under engine.
• Remove oil filter.
• Release hose clamps -arrows-. See Fig 7.
• Remove oil cooler -1-.
  Fig 7: Removing Oil Cooler

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• Remove lower 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.
  Fig 8: Removing Lower Nuts On Engine Mountings

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• Remove front subframe bolts -2- and -3-(left and right).
• Remove bolts -4-.
• Move stabilizer bar downward.
• Remove charge air cooler -2- on right side (release hose connection at top, and 3 rubber mountings).
  Fig 9: Removing Front Subframe Bolts

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• Remove air duct from connector elbow on alternator -3-.
• Disconnect cable from terminal 30/B+ -1-. Tightening torque: 16 Nm. See Fig 10.
• Disconnect cable from terminal D+ -2-. Tightening torque: 4 Nm
  Fig 10: Removing Air Duct From Alternator Connector Elbow

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• Remove hex socket head bolt -1- and securing nut -2-. Tightening torque: 45 Nm
• Loosen bolt -3-. Tightening torque 22 Nm
• Remove alternator -4- from below.
  Fig 11: Removing Hex Socket Head From Alternator

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1. Remove air line -1-.
   Fig 12: Removing Air Line

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2. Mounting for oil line and air conditioner lines
3. Mounting on cylinder block
4. Release hose clamp

• Disconnect cable from terminal 30/B+ -1-. Tightening torque: 16 Nm
• Disconnect connector for terminal 50 -2-.
• Remove right wheel.
  Fig 13: Disconnecting Cables From Starter Terminals

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• Remove top bolt -1- from right wheelhousing. Tightening torque: 65 Nm
• Remove lower bolt (accessible from engine side). Tightening torque: 65 Nm
• Remove starter from front of vehicle.
  Fig 14: Removing Top Bolt -1- From Right Wheelhousing

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  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 oil pan.
• Disconnect return lines for turbocharger from upper section of oil pan.
  Fig 15: Removing Lower Section Of Oil Pan

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• Unbolt cover plate -2- for oil pump sprocket.
  NOTE:

  • When loosening bolt -2- securing cover plate, counter-hold at welded nut.
  • When installing, make sure that the plate engages in position -arrows-.
  Fig 16: Locating Cover Plate For Oil Pump Sprocket

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• Unbolt two oil supply lines, and pull longer of two lines downward to disconnect from upper section of oil pan.
  Fig 17: Locating Oil Supply Lines

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• Unbolt oil pump from engine so that shorter oil supply line can be disconnected (do not remove oil pump).
• Remove bolts securing upper section of oil pan to transmission.
• Unbolt upper section of oil pan from engine.

Fig 18: Locating Bolts For Upper Section Of Oil Pan

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