Upper Oil Pan

Special tools and workshop equipment required

Protective eyewear
Hand drill with plastic brush attachment
Sealant

Removing

Engine fastened to the engine and transmission holder. Refer to ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER .
Engine oil drained. Refer to Maintenance Procedures .

-- Remove timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

-- Remove the power take-off drive chain. Refer to POWER TAKE-OFF DRIVE CHAIN .

-- Remove the belt pulley side sealing flange. Refer to SEALING FLANGE, BELT PULLEY SIDE .

-- Remove the oil pump. Refer to OIL PUMP .

-- Remove the bolts -1 through 4-.

Fig 1: Identifying Upper Oil Pan, Tightening Specifications and Sequence

Courtesy of AUDI OF AMERICA, LLC

-- Carefully loosen the upper oil pan from the bond and press it off the cylinder block alignment bushings.

Installing

For the correct tightening specifications, refer to UPPER OIL PAN OVERVIEW .

NOTE:

Replace seals, gaskets and O-rings.

-- Remove any old sealant from the grooves on the upper oil pan as well as from the sealing surfaces.

CAUTION:

Risk of contaminating lubricating system.

Cover open parts of engine.

WARNING:

Risk of eye injury.

Wear protective eyewear.

-- Remove sealant residue on the upper section of the oil pan and the cylinder block, for example using a rotating plastic brush.

Fig 2: Identifying Rotating Plastic Brush For Removal Of Sealant From Upper Part Of Oil Pan And Cylinder Block

Courtesy of AUDI OF AMERICA, LLC

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

-- Make sure the dowel sleeves are inside the cylinder block; it not install them.

NOTE:

Note the expiration date of the sealing compound.

-- Cut the tube nozzle at the front marking (nozzle diameter approximately 1.5 mm).

Fig 3: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1.5 mm)

Courtesy of AUDI OF AMERICA, LLC

-- Install the gaskets -1- and -2- into the upper oil pan.

Fig 4: Identifying Sealant Beads -Arrows-

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant bead thicker than specified.

-- Apply the sealant beads -arrows- to the clean sealing surface on the upper oil pan as shown in the illustration.

The grooves -arrows- of sealing surfaces must be completely filled with sealant.
The sealant beads must be 1.5 to 2.0 mm above the sealing surface.

NOTE:

Install the upper oil pan within five minutes of applying the sealant.

-- Position the upper oil pan and tighten the bolts. Refer to Figure.

Fig 5: Identifying Upper Oil Pan, Tightening Specifications and Sequence

Courtesy of AUDI OF AMERICA, LLC

The rest of the installation is performed in reverse order of removal, noting the following:

-- Install the oil pump. Refer to OIL PUMP .

-- Install the belt pulley side sealing flange. Refer to SEALING FLANGE, BELT PULLEY SIDE .

-- Install the power take-off drive chain. Refer to POWER TAKE-OFF DRIVE CHAIN .

-- Install timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

-- Fill engine oil and check oil level. Refer to Maintenance Procedures .