Oil pan (upper part), removing and installing

WARNING: This page is about a different car, the 2006 Audi A8, 2005 Audi A8, and 2004 Audi A8. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Oil Pan (Upper Part), Removing And Installing

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Special tools, testers and auxiliary items required

Engine support bridge 10 - 222 A
Shackle 10 - 222 A/12
Adapter 10-222 A/21
Pry Lever - Rmv Outside Mirror 80 - 200

Old oil collecting and extracting device V.A.G 1782
Hand drill with plastic brush attachment
Protective glasses
Silicone sealant

Block of wood, 50 x 50 x 50 mm

Removing

NOTE:

Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode → 43 - Self Leveling Suspension .

Fig 2: Identifying Rubber Seal & Plenum Chamber Cover

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Remove rubber seal for plenum chamber cover - 1 -.
Remove plenum chamber cover - 2 - and - 3 -.

Fig 3: Removing Engine Cover

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Remove engine cover - 1 - upward.

Fig 4: Identifying Clips & Bolt

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Remove clips - 1 - using Pry Lever - Rmv Outside Mirror 80 - 200.
Remove bolt - 2 - and remove cover.

NOTE:

Note clips when installing - arrows -.

Fig 5: Removing Left Cover By Removing Bolt And Expanding Rivet

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Remove left cover by removing bolt - 1 - and removing expanding rivet - 2 - using Pry Lever - Rmv Outside Mirror 80 - 200.

NOTE:

Note clips when installing - arrows -.

Fig 6: Identifying Cover Bracket, Bracket For A/C Line & Bracket For A/C Line

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Remove cover bracket - 1 -.
Remove bracket for A/C line - 2 -.
Unclip bracket for A/C line - 3 -.

Fig 7: Removing Dome Brace Bolts

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Remove bolts - 4 - on left and right.

Fig 8: Securing Engine Support Bridge 10 - 222 A With Adapters 10 - 222 A/21 At Suspension Strut Domes

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Secure engine support bridge 10 - 222 A with adapters 10 - 222 A/21 at suspension strut domes.
Install adapters 10 - 222 A/21 to dome brace - 3 - at left and right.

Support for left and right side of vehicle is marked.
The center support point is secured on front bolts for dome brace.
Knurled-head screw - 1 - must be turned downward far enough so that supporting plate makes contact on suspension strut dome.

Fig 9: Securing Shackles 10 - 222 A/12 To Right Rear Engine Lifting Eyelets

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Secure shackles 10 - 222 A/12 to right rear engine lifting eyelets.
Hook shackles 10 - 222 A/12 into spindles of engine support bridge 10 - 222 A.
Slightly pre-tension engine using engine support bridge spindles.

For vehicles with parking/auxiliary heater:

Fig 10: Removing Bolts For Exhaust Pipe Of Parking Heater/Auxiliary Heater On Noise Insulation

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Remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

All

Fig 11: Locating Mounting Parts And Removing Noise Insulation

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Loosen mounting parts - 1 - and remove noise insulation.

Fig 12: Removing Bolts On Left/Right

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Remove bolts - 1 through 3 - on left and right.
Lower engine carrier.

Fig 13: Disconnecting Water Pipe From Oil Pan

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Disconnect water pipe - arrow - from oil pan.

Fig 14: Disconnecting Water Pipe From Engine Block

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Disconnect water pipe from engine block - arrow -.
Drain coolant → Cooling system, draining and filling .

Fig 15: Removing Bolts And Coolant Drain Tube

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Remove bolts - 1 - and - 2 - and remove coolant drain tube.

Fig 16: Identifying Guide Tube With Oil Dipstick & Bolts

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Remove bolt - 1 - and loosen bolt - 2 - a few rotations.
Remove guide tube - 3 - with oil dipstick.

Fig 17: Identifying Left Level Control System Sensor Electrical Harness Connector & Left/Right Control Arms Coupling Rod

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Remove coupling rod - 1 - at left and right control arms.
Pull subframe downward.

Fig 18: Placing Block Of Wood Between Front Subframe Mount And Body

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Place block of wood (height - a - = 50 mm) between front subframe mount and body.

NOTE:

To avoid measuring wheel alignment, the subframe must only be loosened and lowered at the front end.

Place oil receptacle beneath.
Drain engine oil.

Fig 19: Disconnecting Electrical Harness Connector At Oil Level Thermal Sensor G266

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Disconnect electrical harness connector at Oil Level Thermal Sensor G266 - 1 -.
Remove lower section of oil pan - arrow -.

Fig 20: Removing Baffle Plate

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Remove baffle plate - arrows -.
Remove tensioning ring.

Fig 21: Disconnecting Intake Connection From Oil Pump

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Disconnect intake connection - arrow - from oil pump.

Fig 22: Removing/Installing Engine/Transmission Connecting Bolts In Area Of Oil Pan (Upper Part)

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Remove engine/transmission connecting bolts - arrows - in area of oil pan (upper part).

Fig 23: Removing/Installing Oil Pan Bolts (Upper Part)

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Remove bolts - 1 - and - 2 - from oil pan (upper part).
Press upper part of oil pan from alignment pins of cylinder block.

Installing

Fig 24: Using Rotating Plastic Brush To Remove Remaining Sealant From Oil Pan (Upper Part) And Cylinder Block

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Using e.g. rotating plastic brush, remove remaining sealant from upper part of oil pan and from cylinder block.

CAUTION: Wear safety glasses.

Clean sealing surfaces, must be free of oil and grease.

Fig 25: Cutting Tube Nozzle At Front Marking

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Cut tube nozzle at front marking (jet dia. approx. 1 mm).

Fig 26: Applying Silicon Sealant Bead To Clean Sealing Surfaces Of Oil Pan (Upper Section)

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Apply silicon sealant bead to clean sealing surfaces of oil pan (upper section) as shown in illustration.

Thickness of sealant bead: approx. 1.5 mm

NOTE:

The oil pan (upper part) must be installed within 5 minutes after application of silicone sealant.
Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer.
Apply sealant bead in area of cylinder block bore as well as rear sealing flange - arrows - extremely carefully.

Fig 27: Removing/Installing Oil Pan Bolts (Upper Part)

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Attach upper part of oil pan and pre-tighten all bolts - 1 - and - 2 - of oil pan (upper part) to cylinder block in diagonal sequence to 5 Nm.
Tighten bolts - 1 - and bolts - 2 - in diagonal sequence.

Fig 28: Removing/Installing Engine/Transmission Connecting Bolts In Area Of Oil Pan (Upper Part)

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Install engine/transmission connecting bolts - arrows - in area of oil pan (upper part).
Tighten bolts for oil pan (upper part) to transmission.
Replace oil dipstick guide tube O-ring.

Further installation is in reverse order of removal, note the following:

NOTE:

Replace seals and O-rings.
Secure all hose connections using hose clamps of series-production status
Hose connections and charge air system hoses must be free of oil and grease before installing. Do not use lubricant under any circumstances.

Install oil pan (lower part) → Oil Level Thermal Sensor G266 , removing and installing .
Install subframe → 40 - FRONT SUSPENSION .
Add engine oil and check oil level.
Fill with coolant.

Torque specifications

Component		Nm
Oil pan (upper part) to cylinder block and sealing flange	M7	14
	M8	22
Upper part of oil pan to transmission		65
Baffle plate to upper part of oil pan		10
Oil drain plug		50
Engine mount to subframe		23
Oil dip stick guide tube to cylinder head		22
Engine carrier to engine mount		23
Engine carrier to chassis		68
Coolant drain tube to	Cylinder block	32,5
	Oil pan (upper section)	10