Audi Cars 1999-05

Oil Pan

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Removal & Installation



1.8L Engine

The following tools, supplies and equipment are necessary to complete this procedure:



Tool Nos. 10-222A engine support column and 10-222A/1 engine bracket or their equivalents
 
Tool No. 2024A engine sling, or its equivalent
 
Tool No. 3249 puller, or its equivalent
 
Tool No. VAG12O2A engine hoist, or its equivalent
 
Part No. AMV 17400401 sealant, or its equivalent
 
Replacement gaskets
 


NOTE
Gaskets must always be replaced.

  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the lower engine shield.
  6.  
  7. Drain the engine oil into a suitable container.
  8.  


WARNING
Before removal of the ribbed belt, note the direction of its rotation using a felt-tipped marker or chalk. Reversing the rotational direction a used belt could destroy the belt.

  1. Remove the fasteners for the multi-ribbed belt tensioner for A/C compressor. For additional information, please refer to the following topic(s): General Information And Maintenance, Routine Maintenance And Tune-Up.
  2.  
  3. Loosen the tensioner and remove the belt, then remove the belt pulley.
  4.  
  5. Remove torque support bracket from the front of the engine.
  6.  
  7. Remove the left brace from the torque support bracket, then remove the support bracket from the
  8.  
  9. Cut the tie straps for the starter motor cable guide bracket, open the guide bracket and remove the cable.
  10.  
  11. Remove the air hose from the turbocharger from the air guide tube in the hood lock carrier.
  12.  
  13. Remove the lower engine mount-to-subframe mounting nuts.
  14.  
  15. Remove the engine trim covers.
  16.  
  17. Place Tool No. 10-222A engine support brace, or its equivalent, on the inner fender mounting edges.
  18.  
  19. Remove the mounting eyelet from Tool No. 2024A engine sling, or its equivalent.
  20.  
  21. Insert the lock bolt into the center bore of Tool No. 2024A engine sling, or its equivalent, and secure using a lock pin or cotter key.
  22.  
  23. Install Tool No. 2024A engine sling bolt to Tool No. 10-222A engine support bracket spindle, or their equivalents.
  24.  
  25. Attach Tool No. 2024A engine sling to mounting eyelets at the front and rear of the engine.
  26.  


CAUTION
Make sure the mounting hooks and pins for the engine sling are secured with the positioning lock.

  1. Lift up engine as far as possible without severely stretching or damaging the pipes or coolant hoses using Tool No. 10-222A engine support bracket spindle, or its equivalent.
  2.  


WARNING
Lift engine as far as possible without unnecessary stretching or causing damage to any pipes or coolant hoses. Inspect the clearance of the viscous fan, and if necessary remove.

  1. Remove the viscous fan clutch and place forward in fan frame. For additional information, please refer to the following topic(s): Engine and Engine Overhaul, Engine Fan Removal.
  2.  
  3. Using Tool No. VAG12O2A engine hoist, or its equivalent, support the subframe. Then, remove the inner and outer bolts from the left and right front mounting brackets located just forward of the front sway bar bushing mount, then remove the third bolt on both sides located just behind the sway bar bushing mount.
  4.  


NOTE
Loosen or lower the sub frame at the front to prevent from altering the front wheel alignment.

  1. Slowly and carefully lower the engine hoist supporting the lower subframe, then remove the engine hoist and swing the stabilizer down.
  2.  
  3. If equipped with a manual transmission, loosen the left transmission mount nut until it is flush with the lowermost edge of mounting bolt, (about four revolutions).
  4.  
  5. If equipped with an automatic transmission, locate the left side transmission mount. Loosen but Do NOT remove the rear flange bolt, then remove the front flange bolt.
  6.  
  7. On all vehicles, locate the right side transmission mount. Loosen, but Do NOT remove, the rear flange bolt, then remove the front flange bolt.
  8.  
  9. Disconnect the oil return line for the turbocharger from the oil pan.
  10.  
  11. Remove the oil pan mounting fasteners, and then remove the oil pan. On models equipped with manual transmissions, to access the rear oil pan fasteners, rotate the engine until the recessed area of the flywheel exposes the rear fasteners. If necessary, use a hex ball socket tool to remove the rear fasteners such as Tool No. 3249, or its equivalent.
  12.  
  13. If the oil pan resists removal, install two fasteners opposite one another about 4-5 turns and using a suitable rubber mallet or plastic faced dead blow hammer, tap lightly around the sides of the oil pan.
  14.  



Click image to see an enlarged view

Fig. The engine support Tool Nos. 10-222 A and 2024 A shown supporting the engine



Click image to see an enlarged view

Fig. The flywheel is relieved to allow for fastener access on 1.8L engines with a manual transmission



Click image to see an enlarged view

Fig. An exploded view of the oil pan, oil pump, and related components-1.8L engine

To install :

  1. Installation is in reverse order of removal noting the following:
  2.  


    Thoroughly clean the sealing surfaces of the engine block and oil pan before installation.
     
    Replace all gaskets and 0-rings
     
    Apply a light film of Part No. AMV 17400401 sealant, or its equivalent, on front and rear contact surfaces and seams of oil seal housings.
     


Observe the following tightening torque:



Oil pan-to-engine block, M6: 88 inch lbs. (10 Nm)
 
Oil pan-to-engine block, M10: 33 ft. lbs. (45 Nm)
 
Oil pan-to-transmission: 33 ft. lbs. (45 Nm)
 
Engine mount to subframe: 18 ft. lbs. (25 Nm)
 
Torque support-to-engine bracket: 18 ft. lbs. (25 Nm)
 
Side brace-to-torque support bracket: 18 ft. lbs. (25 Nm)
 
Oil drain plug: 37 ft. lbs. (50 Nm)
 
Oil return line-to-oil pan: 88 inch lbs. (10 Nm)
 
Transmission mount-to-subframe: 17 ft. lbs. (23 Nm)
 

  1. Tighten oil pan-to-engine block bolts in 2 stages and using a crisscross pattern working from the center outward. Tighten as follows:
  2.  
    1. Oil pan-to-engine block M6 bolts, Stage 1, 44 inch lbs. (5 Nm).
    2.  
    3. Oil pan to transmission bolts, 33 ft. lbs. (45 Nm).
    4.  
    5. Oil pan-to-engine block, M10 bolts, 33 ft. lbs. (45 Nm).
    6.  
    7. Oil pan-to-engine block M6 bolts, Stage 2, 88 inch lbs. (10 Nm).
    8.  

  3. Install the subframe.
  4.  
  5. Install the torque support onto the rubber buffer for the torque support and tighten bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the drive belts, then add and top off the engine oil as necessary. For additional information, please refer to the following topic(s): General Information And Maintenance, Routine Maintenance And Tune-Up, Fluids And Lubricants.
  8.  
  9. Check for any fluid leaks and repair as necessary.
  10.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     
    Accessory drive belts and the air conditioning belt tension pulley
     
    Torque support stop and side brace
     
    Starter wiring
     
    Hose from the turbocharger at the air guide tube in the lock carrier
     
    Bottom nuts from the lower engine mount
     
    Top engine cover

    Click image to see an enlarged view

    Fig. The engine must be supported, because the subframe mounting bolts must be loosened-1.8L engine

     

  6.  
  7. Install the Engine Support Bridge tool 10-222A and the Engine Sling tool 2024A; then, lift the engine as far a possible.
  8.  
  9. Support the subframe.
  10.  
  11. Remove or disconnect the following:

    Front bolts No. 2 and 3
     
    Bolt No. 1 from the subframe
     

  12.  
  13. Slowly lower the subframe.
  14.  
  15. If equipped with a manual transaxle, loosen the left transaxle mount nut until it is aligned with the lower edge of the bolt (approx. 4 turns).
  16.  
  17. If equipped with an automatic transaxle, loosen the rear bolt for the left transaxle mount several turns, then remove the front bolt for the transaxle mount.
  18.  
  19. At the right transaxle mount, loosen the rear bolt mount several turns and remove the front bolt.
    NOTE
    If equipped with a manual transaxle, both of the rear bolts on the oil pan can be accessed through the opening on the flywheel. Turn the flywheel as needed.



    Click image to see an enlarged view

    Fig. If equipped with a manual transaxle, align the flywheel as shown to remove the rear oil pan bolts-1.8L engine

  20.  
  21. Remove the oil pan.
  22.  
  23. Clean all gasket mating surfaces.
  24.  

To install:

  1. Apply sealant to the front and rear contact areas of the oil seal carriers.
  2.  
  3. Install or connect the following:

    New oil pan gasket
     
    Oil pan
     

  4.  
  5. Tighten the oil pan bolts as follows:

    Oil pan-to-engine bolts: 44 inch lbs. (5 Nm)
     
    M10 bolts between the oil pan and engine: 33 ft. lbs. (45 Nm)
     
    M6 bolts between the oil pan and engine: 84 inch lbs. (10 Nm)

    Click image to see an enlarged view

    Fig. Subframe bolt tightening sequence-1.8L engine

     

  6.  
  7. Tighten the subframe bolts/nuts using the illustration as follows:

    Bolts 2 and 5: 81 ft. lbs. (110 Nm) plus a 1 / 4 (90 degree) turn
     
    Bolt 6: 55 ft. lbs. (75 Nm)
     
    Bolt 1: 17 ft. lbs. (23 Nm)
     
    Nuts 3 and 4: 30 ft. lbs. (40 Nm)
     

  8.  
  9. Install or connect the following:

    Subframe-to-transaxle. Torque the nuts to 17 ft. lbs. (23 Nm)
     
    Engine mount-to-subframe. Torque the nuts to 18 ft. lbs. (25 Nm)
     
    Turbocharger air hose
     
    Starter wiring
     
    Torque support stop and brace. Torque the fasteners to 18 ft. lbs. (25 Nm)
     
    Air conditioning belt tensioner
     
    Accessory drive belts
     
    Negative battery cable
     

  10.  
  11. Fill the engine with oil and check the level.
  12.  
  13. Start the vehicle and check for leaks, then recheck the engine oil level.
  14.  
  15. Install or connect the following:

    Engine cover
     
    Undercover
     

  16.  

2.7L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. On A6 models, place the hood lock carrier assembly in the service position.
  6.  
  7. Disconnect the battery negative cable.
  8.  
  9. Drain engine oil
  10.  
  11. Remove or disconnect the following:

    Engine undercover
     
    Accessory drive belt
     
    Air conditioning lines from oil pan
     
    Air conditioning compressor lines
     
    Oil pan
     

  12.  

To install:

  1. Install or connect the following:

    New oil pan gasket
     
    Oil pan
     
    Tighten the oil pan bolts to 84 inch lbs. (10 Nm) working from the center outward
     
    Air conditioning compressor lines
     
    Air conditioning lines
     
    Accessory drive belt
     
    Engine undercover
     
    Install lock carrier in normal position
     
    Negative battery cable
     

  2.  

2.8L Engine

During the production of model year 1998 Audi A4 models, the oil pan, oil pump drive and location were changed. The following is a comparison of the changes. Note, the Vehicle Identification Number (VIN) shown represents the last six digits of the serial number for model year 1998, code 'W'. For additional information, please refer to the following topic(s): General Information And Maintenance, Serial Number Identification.

1996-early 1998 A4 models:



VIN No. (last 6 digits): up to 005000
 
Outer oil pan surface: Finned
 
Oil pump location: Front engine housing
 
Oil pump drive: Keyed to front of crankshaft
 

Late 1998-00 A4 models:



VIN No. (last 6 digits): after 005001
 
Outer pan surface: smooth
 
Oil pump location: Engine oil sump
 
Oil pump drive: Chain driven via crankshaft sprocket
 
Oil filter size (diameter) increased
 


NOTE
The 1998-00 Passat models all use the later style of oil pan (smooth surface) and oil pump (chain driven) system.

To remove the oil pan, proceed as follows:

  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Remove the engine oil dipstick, and then remove the dipstick tube located near the cylinder head.
  4.  
  5. Remove the lower engine shield.
  6.  
  7. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  8.  
  9. Drain the engine coolant from the radiator and the engine block into a suitable container. The engine block drain plug is on the bottom rear portion of the engine near the oil pan-to-engine block gasket surface and the engine flywheel.
  10.  
  11. Drain the engine oil into a suitable container.
  12.  
  13. On 1996-early 1998 A4 models, disconnect the oil line bracket from the right side of the engine oil pan.
  14.  
  15. On late 1998-00 A4 and Passat models with automatic transmissions, remove the oil cooler line bracket from the right side of the oil pan.
  16.  
  17. Place Tool No. 10-222A engine support brace, or its equivalent, on the inner fender mounting edges.
  18.  
  19. Remove the mounting eyelet from Tool No. 2024A engine sling, or its equivalent.
  20.  
  21. Insert the lock bolt into the center bore of Tool No. 2024A engine sling, or its equivalent and secure using a lock pin or cotter key.
  22.  
  23. Install Tool No. 2024A engine sling bolt to Tool No. 10-222A engine support bracket spindle, or their equivalents.
  24.  
  25. Attach Tool No. 2024A engine sling to mounting eyelets at the front and rear of the engine.
  26.  


CAUTION
Make sure the mounting hooks and pins for the engine sling are secured with the positioning lock.

  1. Lift up engine as far as possible without severely stretching or damaging the pipes or coolant hoses using Tool No. 10-222A engine support bracket spindle, or its equivalent.
  2.  


WARNING
Lift the engine as far as possible, but without any unnecessary stretching to any pipes or coolant hoses, or damage will result.

  1. Cut the tie straps for the starter motor cable guide bracket, open the guide bracket and remove the cable.
  2.  
  3. Remove torque support bracket from the front of the engine.
  4.  
  5. Remove the coolant line from the oil pan at the front of the engine.
  6.  
  7. Disconnect the oil pressure switch electrical connector from the left side of the oil pan.
  8.  
  9. Remove the oil cooler lines from the oil cooler beneath the oil filter.
  10.  
  11. Matchmark the left and right lower engine mount-to-subframe for proper re-alignment during installation.
  12.  
  13. Remove the inner and outer bolts from the left and right front mounting brackets located just forward of the front sway bar bushing mount, then remove the third bolt on both sides located just behind the sway bar bushing mount.
  14.  


NOTE
Loosen or lower the sub frame at the front to prevent from altering the front wheel alignment.

  1. Slowly and carefully lower the stabilizer bar downward.
  2.  
  3. Remove the starter motor.
  4.  
  5. Remove the oil pan mounting fasteners, and then remove the oil pan.
  6.  
  7. If the oil pan resists removal, install two fasteners opposite one another about 4-5 turns and using a suitable rubber mallet or plastic faced dead blow hammer, tap lightly around the sides of the oil pan.
  8.  

If removing the UPPER portion of the oil pan:

  1. On 1996-early 1998 A4 models:
  2.  
    1. Make sure to remove the two M6 and M8 fasteners that are installed vertically in the rear of the upper part of the oil pan in front of the engine-to-transmission mating surfaces.
    2.  
    3. Remove the upper oil pan to transmission fasteners that are installed vertically in the rear of the upper part of the oil pan in front of the engine-to-transmission mating surfaces.
    4.  
    5. Remove the remaining upper oil pan to engine mounting fasteners and remove the upper oil pan.
    6.  

  3. On late 1998-00 A4 and Passat models:
  4.  
    1. Remove the mounting fasteners for the oil pump supply tube retainers.
    2.  
    3. Remove the larger of the two oil tubes.
    4.  
    5. Remove the oil pump mounting bolts and move the pump enough to remove the shorter oil supply tube. Do NOT remove the oil pump.
    6.  
    7. Remove the upper oil pan to transmission fasteners that are installed vertically in the rear of the upper part of the oil pan in front of the engine-to-transmission mating surfaces.
    8.  
    9. Remove the remaining upper oil pan to engine mounting fasteners and remove the upper oil pan.
    10.  




Click image to see an enlarged view

Fig. An exploded view of the upper and lower oil pan and related components-2.8L 5V V6 engine shown



Click image to see an enlarged view

Fig. The oil supply tubes are held to the upper oil pan by retaining brackets. Apply a locking agent to the retaining bracket fasteners upon assembly-chain driven oil pumps



Click image to see an enlarged view

Fig. The oil pump is attached to the upper oil pan. The pump fasteners are removed and the pump moved to remove the smaller oil delivery tube-chain driven oil pumps

To install :

  1. Thoroughly clean the mating surface of the oil pan using a rotating plastic brush to remove any residual sealant from the oil pan gasket surface.
  2.  


CAUTION
When using a plastic rotating brush, wear eye protection. Residual debris may be flung during removal.

  1. The balance of installation is in reverse order of removal noting the following:
  2.  


    Thoroughly clean the sealing surfaces of the engine block and oil pan before installation.
     
    Replace all gaskets and 0-rings
     



WARNING
After applying the oil pan sealant Part No. D 454 300 A2, or its equivalent. The oil pan must be installed within 5 minutes!

  1. On 1996-early 1998 A4 models:
  2.  
    1. Apply a light film of the recommended sealant on the front and rear contact surfaces and the seams of oil seal housings.
    2.  

  3. On late 1998-00 A4 and Passat models, if the upper oil pan was removed:
  4.  
    1. Apply an 1 / 8 inch (3 mm) continuous bead of the proper sealant on the engine block. Apply the sealant such that it is on center with the fastener holes, and applied to the inside circumference of the fastener holes.
    2.  
    3. Immediately install the upper oil pan and tighten the oil pan-to-engine block fasteners to 44 inch lbs. (5 Nm).
    4.  
    5. Tighten oil pan-to-engine block bolts in 2 stages and using a crisscross pattern working from the center outward. Tighten as follows:
    6.  
    7. Oil pan-to-engine block M6 bolts, Stage 1, 44 inch lbs. (5 Nm).
    8.  
    9. Oil pan-to-engine block M6 bolts, Stage 2, 88 inch lbs. (10 Nm).
    10.  
    11. Tighten the oil pan-to-transmission M10 fasteners to 33 ft. lbs. (45 Nm)
    12.  
    13. Tighten the oil pan-to-engine block bolts in 2 stages and using a crisscross pattern working from the center outward. Tighten the M6 bolts as follows:
    14.  


      Stage 1: 88 inch lbs. (10 Nm)
       
      Stage 2: 11 ft. lbs. (15 Nm)
       

    15. Install the short oil tube to the oil pump and upper oil pan and install the oil pump. Apply a locking agent to the oil pump mounting bolts and tighten to 18 ft. lbs. (25 Nm).
    16.  
    17. Install the long oil tube and apply a locking agent both of the oil tube retainer bracket bolts and tighten to 88 inch lbs. (10 Nm).
    18.  
    19. Tighten the oil pan-to-engine block M10 fasteners to 33 ft. lbs. (45 Nm)
    20.  

  5. Install the lower oil pan using a new gasket.
  6.  

Observe the following tightening torque:



Oil pan-to-engine block, M6: 88 inch lbs. (10 Nm)
 
Oil pan-to-engine block, M10: 33 ft. lbs. (45 Nm)
 
Oil pan-to-transmission M8: 18 ft. lbs. (25 Nm)
 
Oil pan-to-transmission M10: 33 ft. lbs. (45 Nm)
 
Coolant line-to-oil pan: 88 inch lbs. (10 Nm)
 
Engine mount to subframe: 18 ft. lbs. (25 Nm)
 
Torque support-to-engine bracket M8: 18 ft. lbs. (25 Nm)
 
Torque support-to-engine bracket M10: 33 ft. lbs. (45 Nm)
 
Side brace-to-torque support bracket: 15 ft. lbs. (20 Nm)
 
Oil drain plug: 22 ft. lbs. (30 Nm)
 

  1. Tighten oil pan-to-engine block bolts in 2 stages and using a crisscross pattern working from the center outward. Tighten as follows:
  2.  
    1. Oil pan-to-engine block M6 bolts, Stage 1, 44 inch lbs. (5 Nm).
    2.  
    3. Oil pan-to-engine block M6 bolts, Stage 2, 88 inch lbs. (10 Nm).
    4.  

  3. Install the torque support onto the rubber buffer for the torque support and tighten bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Fill and top off the engine oil and engine coolant as necessary. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants.
  6.  
  7. Check for any fluid leaks and repair as necessary.
  8.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Oil pan bolts
     
    Oil pan from the engine
     

  6.  

To install:

  1. Be sure the gasket surface is flat.
  2.  
  3. Install or connect the following:

    New oil pan gasket
     
    Oil pan. Torque the bolts in a crisscross pattern to 11 ft. lbs. (15 Nm)
     

  4.  
  5. Fill the engine with oil.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. For vehicles with auxiliary heater, remove bolts for exhaust pipe of parking heater/auxiliary heater at engine undercover.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the battery negative cable.
  8.  
  9. Drain engine oil
  10.  
  11. Remove or disconnect the following:

    Engine undercover
     
    Accessory drive belt
     
    Bracket for automatic transmission fluid lines
     
    Bracket for air conditioning lines
     
    Connector at oil level sensor
     
    Oil pan
     

  12.  

To install:

  1. Apply silicone sealant to oil pan sealing surface
  2.  
  3. Install or connect the following:

    Oil pan
     
    Tighten the oil pan bolts diagonally to 84 inch lbs., (10 Nm)
     
    Air conditioning lines bracket
     
    Automatic transmission fluid lines bracket
     
    Accessory drive belt
     
    Engine undercover
     
    Negative battery cable
     

  4.  

3.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Drain engine oil
  6.  
  7. Remove or disconnect the following:

    Center and right sound insulation
     
    Oil thermal sensor
     
    Secondary air injection pump with bracket
     
    Oil pan
     

  8.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Tighten the oil pan bolts in diagonal sequence initially to 44 inch lbs. (5 Nm)
     
    Tighten bolts for sump/transmission to 30 ft. lbs. (40 Nm) Use new bolts
     
    Tighten the oil pan bolts in diagonal sequence to 105 inch lbs. (12 Nm)
     

  2.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Remove the engine undercover sound insulation.
  6.  
  7. Drain engine oil
  8.  
  9. Remove or disconnect the following:

    Oil thermal sensor
     
    Oil pan
     

  10.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Tighten the oil pan bolts in diagonal sequence initially to 9 Nm
     
    Tighten the oil pan drain plug to 30 Nm.
     

  2.  

4.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the engine from the vehicle and mount it on a suitable workstand.
  4.  
  5. Remove or disconnect the following:

    Lower oil pan
     
    Upper oil pan
     
    Honeycomb baffle
     

  6.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Upper oil pan bolts: 89 inch lbs. (10 Nm)
     
    Lower oil pan bolts: 89 inch lbs. (10 Nm)
     

  2.  

 
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