Oil pan (upper part), removing and installing: Removing

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Lock carrier in service position. Refer to Lock carrier, moving into service position .

WARNING:

Observe safety precautions when disconnecting the battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

See Caution before beginning repairs on the electrical system. Refer to Lubrication system components, removing and installing

Switch ignition off and disconnect battery Ground (GND) strap.
Remove ribbed belt. Refer to Ribbed belt, removing and installing .

Fig 1: Removing Air Filter Housing

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Remove air filter housing (arrows).

Fig 2: Identifying Bolts, Hose From Line Of Secondary Air Injection

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Remove bolts -1- and -3-.
Disconnect hose -4- from line of secondary air injection.
Pull out guide tube for oil dipstick -2- from oil pan (upper part) toward top and swing it forward for removal.

Fig 3: Positioning 10-222A Engine Support Bridge On Bolted Flanges Of Fenders

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Position 10-222A engine support bridge on bolted flanges of fenders.

Fig 4: Removing Eyelet For 2024A Engine Sling

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Remove eyelet for 2024A engine sling.
Insert bolt -1- in center hole of 2024A Engine sling and secure with a cotter pin.
Attach bolt for 2024A Engine sling at 10-222A Engine support bridge spindle.
Attach 2024A Engine sling to sling clamps at front and rear of engine.

WARNING:

Take-up hooks and pins at engine sling must be secured using securing pins (arrows) as shown in illustration.

Slightly pre-tension engine using engine support bridge spindle.
Place engine oil drip tray beneath engine.
Drain engine oil.

Fig 5: Loosening Oil Filter Using Tension Strap

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Loosen oil filter (arrow) using tension strap; e.g. Hazet 2171-1.
Place VAG1306 Drip tray beneath engine.

Fig 6: Clamping Coolant Hoses Using 3094 Hose Clamps

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Clamp coolant hoses -2- and -3- using 3094 hose clamps.
Disconnect coolant hoses from oil cooler -1-.
Remove oil cooler.

Fig 7: Disconnecting Electrical Harness Connector At Secondary Air Injection (AIR) Pump Motor -V101-

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Disconnect electrical harness connector -2- at Secondary Air Injection (AIR) pump motor -V101- ,-1-.
Remove Secondary Air Injection (AIR) pump at longmember.

WARNING:

Do not open refrigerant circuit for A/C system.

Fig 8: Removing Bolts, Unclip Refrigerant Lines & Allowing Catch Reservoir With Connected Refrigerant Lines To Remain Hanging In Installed Position

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Remove bolts -1- and -2-.
Unclip refrigerant lines (arrows).
Allow catch reservoir -3- with connected refrigerant lines to remain hanging in installed position.

Vehicles with automatic transmission

Fig 9: Removing Union Nuts And Disconnect ATF Lines

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Remove bracket for ATF lines, to do so remove nuts -1- and -2-.

NOTE: Union nuts -3- of ATF lines must not be disconnected.

All

Fig 10: Unbolting Bracket For Refrigerant Line At Oil Pan

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Unbolt bracket for refrigerant line at oil pan (arrow).

NOTE: Depicted in the illustration for a vehicle with manual transmission.

Fig 11: Disconnecting Harness Connector Of Electrical Wire To A/C Compressor Clutch

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Disconnect harness connector -1- of electrical wire to A/C compressor clutch.
Unbolt A/C compressor from bracket (arrows).

Fig 12: Hanging A/C Compressor With Connected Refrigerant Lines To Stabilizer Using Wire

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Hang A/C compressor (arrow) with connected refrigerant lines to stabilizer using wire.

Fig 13: Threaded Connections And Positioning Sleeves On Lower Engine Mounts

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Mark installed positions for threaded assemblies -1- and positioning sleeves -2-.

NOTE: Different mounting holes are available depending upon the installed engine.

Remove lower nuts -1- on left and right engine mounts.

Fig 14: Unclipping Operating Rod For Vehicle Level Sensor At Lower Lateral Control Arm

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If installed, unclip operating rod for vehicle level sensor at lower lateral control arm (arrow).

Fig 15: Starter Wiring Bracket Cable Ties

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Cut cable ties (arrows), open bracket for starter wiring and remove electrical wiring.

Fig 16: Removing Front Bolts From Left And Right Subframe

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Remove front bolts -2- and -3- from left and right sides of subframe. Then remove bolt -1-.

NOTE: Only loosen or lower subframe at front side to avoid having to perform a wheel alignment.

Lower front subframe.

Fig 17: Disconnecting Electrical Harness Connector At Oil Pressure Switch

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Disconnect electrical harness connector at oil pressure switch (arrow).

Fig 18: Unscrewing Bolts And Removing After-Run Coolant Pump At Oil Pan (Upper Part)

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If installed, unscrew bolts -1- and remove after-run coolant pump -2- at oil pan (upper part).

NOTE: Coolant hose to cylinder block can remain connected.

Disconnect electrical lines from generator.

Fig 19: Unscrewing Bolts And Removing Generator

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Remove bolts (arrows) and remove generator.

Fig 20: Removing Left/Right Heat Shields For Drive Axles

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If necessary, remove heat shield for right drive axle -1-.

Fig 21: Removing Electrical Wires From Starter & Disconnecting Ground (GND) Wire

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Remove electrical wires -1- and -2- from starter.

NOTE: Ground (GND) wire -3- remains connected.

Fig 22: Removing Heat Shield From Solenoid, Unscrewing Bolts & Removing Starter

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Remove heat shield -1- from solenoid.
Remove bolts -2- and -3- and remove starter.

Fig 23: Disconnecting Electrical Harness Connector At Oil Level Thermal Sensor

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Disconnect electrical harness connector at Oil level thermal sensor (arrow) and move wiring clear.
Place engine oil drip tray beneath engine, since oil will escape again.

Fig 24: Lower Portion Of Oil Pan

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Unbolt oil pan (lower part) -1- and carefully remove.
Remove oil pump. Refer to Oil pump, removing and installing .

Fig 25: Positioning 10-222A Engine Support Bridge On Bolted Flanges Of Fenders

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Using 10-222A engine support bridge spindle, lift engine slightly.

NOTE: Make sure rear air guide at intake manifold is not damaged when lifting engine.

Fig 26: Identifying Quick-Release Fasteners And Noise Insulation

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Remove quick-release screws -2- and -3- and remove rear sound insulation, if present.

Fig 27: Removing Bracket For Noise Insulation

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Remove bracket for sound insulation (arrows).

Fig 28: Removing Bottom Engine/Transmission Connecting Bolts In Area Of Oil Pan

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Remove bottom engine/transmission connecting bolts in area of oil pan (upper part).
Check whether a 10 mm wrench socket, e.g. 3220 hinged socket, can be slid in through assembly hole (arrows). If necessary rework assembly hole.

Fig 29: Identifying Engine/Transmission Fasteners In Area Of Upper Part Of Oil Pan

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Remove bolts -1- and -2- for oil pan (upper part).
Press oil pan (upper part) off of cylinder block roll pins.

Fig 30: Using Rotating Plastic Brush To Remove Remaining Sealant From Oil Pan (Upper Part) And At Cylinder Block

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Using rotating plastic brush, remove remaining sealant from oil pan (upper part) and at cylinder block.

WARNING:

Wear protective glasses.

Clean sealing surfaces so they are completely free of any oil or grease.