Upper part of oil pan, removing and installing

WARNING: This page is about a different car, the 2008 Audi RS 4 and 2007 Audi RS 4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Old Oil Collecting And Extracting Device V.A.G 1782

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Removing

Remove engine → Engine, removing .
Separate engine and transmission → Engine and transmission, separating .
Secure engine to assembly stand → Engine, securing to assembly stand .
Remove clutch pressure plate →
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
.

Remove dual-mass flywheel → Dual-mass flywheel, removing and installing .
Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .
Remove intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
Remove oil filter housing → Oil filter housing, removing and installing .

Remove lower timing chain cover → Lower timing chain cover, removing and installing .

NOTE:

Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the ribbed belt under operating conditions.

Fig 2: Releasing Ribbed Belt Tension

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To release ribbed belt tension, swing tensioner in direction of - arrow -. Use a lever with ³ /₈ " drive for this.

NOTE:

Ensure lever axle is long enough so that it can be inserted completely in the tensioner.
A suitable lever is, e.g., "Stahlwille 425QR".

Remove ribbed belt.
Release tensioner unit

Fig 3: Removing Bolts & Ribbed Belt Tensioner At Upper Part Of Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove ribbed belt tensioner at upper part of oil pan.

Fig 4: Identifying Coolant Hose, Electrical Connector, Bolt & Heat Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove coolant hose - 1 - from generator.
Disconnect electrical connector - 5 -.
Remove bolt - 4 - and remove heat shield.

NOTE:

Ensure coolant pipes do no slip out because O-rings on removed coolant pipes must be replaced. Reinstall bracket - 3 - after removing heat shield, if necessary.

Remove electrical wire - 2 - from generator.

Fig 5: Removing Generator Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.

NOTE:

If generator is stuck in its bracket, install mounting bolt again up to 2 rotations.
Carefully strike on bolt heads using flat side of hammer - doing this loosens threaded sleeves of generator mount.

Remove generator.

Fig 6: Removing Bolts & Bracket For Generator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove bracket for generator.

Fig 7: Removing Bolts, Front Coolant Pipe At Engine And At Coolant Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove front coolant pipe at engine and at coolant pump.

Fig 8: Disconnecting Electrical Connector At Oil Level Thermal Sensor G266

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connector - 2 - at Oil Level Thermal Sensor G266.
Remove oil pan (lower part) - 1 - and pry out carefully.
Remove oil pump → Oil pump, removing and installing .

Fig 9: Removing Bolts For Upper Section Of Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 to 7 - for upper section of oil pan.
Press upper part of oil pan from alignment pins of cylinder block.

Installing

NOTE:

Replace seals and O-rings.

CAUTION: Wear safety glasses.

Fig 10: Using Rotating Plastic Brush To Remove Remaining Sealant From Oil Pan (Upper Part) And At Cylinder Block

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using rotating plastic brush, remove any remaining sealant from oil pan (upper part) and at cylinder block.
Clean sealing surfaces, they must be free of oil and grease.

Fig 11: Cutting Tube Nozzle At Front Marking

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

Fig 12: Inserting New Seals Into Grooves On Cylinder Block

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert new seals - 1 to 4 - into grooves on cylinder block.

Fig 13: Applying Sealant Beads On Clean Sealing Surfaces Of Upper Part Of Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply sealant beads - 1 - and - 2 - on clean sealing surfaces of upper part of oil pan, as shown in illustration.

Thickness of sealant beads: 2.5 mm.

NOTE:

Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the strainer on intake tube.
The oil pan (upper part) must be installed within 5 minutes after application of sealant.

Fig 14: Removing/Installing Bolts For/To Upper Section Of Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position upper part of oil pan and pre-tighten bolts - 1 to 7 - diagonally to 5 Nm.
Tighten bolts - 1 to 7 - in a diagonal sequence.

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

Install oil pump → Oil pump, removing and installing .
Install coolant pump → Coolant pump, removing and installing .
Install lower section of oil pan Installing .
Install front coolant pipe → Front coolant line, removing and installing .

Install generator →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.
Install lower timing chain cover → Lower timing chain cover, removing and installing .
Install crankshaft seal, timing chain side → Crankshaft seal (timing chain side), replacing .
Install oil filter housing → Oil filter housing, removing and installing .

Install intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
Install left and right timing chain covers → Left and right timing chain covers, removing and installing .
Install dual-mass flywheel → Dual-mass flywheel, removing and installing .
Install clutch pressure plate →
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
.

Install engine → Engine, installing .

Torque specifications

Component	Nm
Upper part of oil pan to cylinder block	14
Generator bracket to cylinder bock	22
Tensioner to upper part of oil pan	9