How to Replace Oil Pan on Audi A4 and VW Passat?

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The procedure is as follows :----

1990-97 Passat Models

NOTE

The oil pan can be removed with the engine in the vehicle. If additional room is needed, support the engine and lower the subframe enough to remove it.

1. Raise and safely support the vehicle and drain the oil.
2. If necessary, support the engine and lower the suspension subframe.

NOTE

On some engines, it may be difficult to access the pan mounting bolts at the flywheel side of the engine without the use of Tool No. 3185, or its equivalent.

3. Loosen and remove the bolts retaining the oil pan.
4. Lower the pan from the engine.

Fig. Exploded view of the oil pan and the components of the oiling system

Fig. View of VR6 cylinder block and oil pan

Fig. The bolts at the flywheel side of the engine may be difficult to access

Fig. Once all the bolts have been removed, lower the oil pan

Fig. Due to extreme heat and pressure, the oil pan gasket may stick to the block and the pan. Do NOT pry on the pan or between the gasket and the block or the windage tray may bend

Fig. The oil pump must be removed before you remove the oil windage tray

To install:

5. Be sure the gasket surface is flat and install the pan with a new gasket.
6. Tighten the retaining bolts in a crisscross pattern as follows:
7. 2.0L (ABA) engine: 15 ft. lbs. (20 Nm)
8. 1.8L (AEB) and 2.8L (AAA) engine: 11 ft. lbs. (15 Nm)
9. Refill the engine with oil. Start the engine and check for leaks.

A4 & 1998-00 Passat Models
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. Raise and safely support the vehicle.
3. Remove the lower engine shield.
4. Drain the engine oil into a suitable container.

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.

5. 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.
6. Loosen the tensioner and remove the belt, then remove the belt pulley.
7. Remove torque support bracket from the front of the engine.
8. Remove the left brace from the torque support bracket, then remove the support bracket from the
9. Cut the tie straps for the starter motor cable guide bracket, open the guide bracket and remove the cable.
10. Remove the air hose from the turbocharger from the air guide tube in the hood lock carrier.
11. Remove the lower engine mount-to-subframe mounting nuts.
12. Remove the engine trim covers.
13. Place Tool No. 10-222A engine support brace, or its equivalent, on the inner fender mounting edges.
14. Remove the mounting eyelet from Tool No. 2024A engine sling, or its equivalent.
15. 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.
16. Install Tool No. 2024A engine sling bolt to Tool No. 10-222A engine support bracket spindle, or their equivalents.
17. Attach Tool No. 2024A engine sling to mounting eyelets at the front and rear of the engine.

CAUTION

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

18. 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.

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.

19. 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.
20. 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.

NOTE

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

21. Slowly and carefully lower the engine hoist supporting the lower subframe, then remove the engine hoist and swing the stabilizer down.
22. 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).
23. 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.
24. On all vehicles, locate the right side transmission mount. Loosen, but Do NOT remove, the rear flange bolt, then remove the front flange bolt.
25. Disconnect the oil return line for the turbocharger from the oil pan.
26. 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.
27. 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.

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

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

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

To install :

28. Installation is in reverse order of removal noting the following:
29. Thoroughly clean the sealing surfaces of the engine block and oil pan before installation.
30. Replace all gaskets and 0-rings
31. 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)

29. Tighten oil pan-to-engine block bolts in 2 stages and using a crisscross pattern working from the center outward. Tighten as follows:
1. Oil pan-to-engine block M6 bolts, Stage 1, 44 inch lbs. (5 Nm).
2. Oil pan to transmission bolts, 33 ft. lbs. (45 Nm).
3. Oil pan-to-engine block, M10 bolts, 33 ft. lbs. (45 Nm).
4. Oil pan-to-engine block M6 bolts, Stage 2, 88 inch lbs. (10 Nm).
30. Install the subframe.
31. Install the torque support onto the rubber buffer for the torque support and tighten bolts to 18 ft. lbs. (25 Nm).
32. 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.
33. Check for any fluid leaks and repair as necessary.

2.8L V6 engines

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. Remove the engine oil dipstick, and then remove the dipstick tube located near the cylinder head.
3. Remove the lower engine shield.
4. 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.
5. 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.
6. Drain the engine oil into a suitable container.
7. On 1996-early 1998 A4 models, disconnect the oil line bracket from the right side of the engine oil pan.
8. 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.
9. Place Tool No. 10-222A engine support brace, or its equivalent, on the inner fender mounting edges.
10. Remove the mounting eyelet from Tool No. 2024A engine sling, or its equivalent.
11. 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.
12. Install Tool No. 2024A engine sling bolt to Tool No. 10-222A engine support bracket spindle, or their equivalents.
13. Attach Tool No. 2024A engine sling to mounting eyelets at the front and rear of the engine.

CAUTION

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

14. 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.

WARNING

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

15. Cut the tie straps for the starter motor cable guide bracket, open the guide bracket and remove the cable.
16. Remove torque support bracket from the front of the engine.
17. Remove the coolant line from the oil pan at the front of the engine.
18. Disconnect the oil pressure switch electrical connector from the left side of the oil pan.
19. Remove the oil cooler lines from the oil cooler beneath the oil filter.
20. Matchmark the left and right lower engine mount-to-subframe for proper re-alignment during installation.
21. 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.

NOTE

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

22. Slowly and carefully lower the stabilizer bar downward.
23. Remove the starter motor.
24. Remove the oil pan mounting fasteners, and then remove the oil pan.
25. 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.

If removing the UPPER portion of the oil pan:

26. On 1996-early 1998 A4 models:
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. 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.
3. Remove the remaining upper oil pan to engine mounting fasteners and remove the upper oil pan.
27. On late 1998-00 A4 and Passat models:
1. Remove the mounting fasteners for the oil pump supply tube retainers.
2. Remove the larger of the two oil tubes.
3. Remove the oil pump mounting bolts and move the pump enough to remove the shorter oil supply tube. Do NOT remove the oil pump.
4. 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.
5. Remove the remaining upper oil pan to engine mounting fasteners and remove the upper oil pan.

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

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

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 :

28. 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.

CAUTION

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

29. The balance of installation is in reverse order of removal noting the following:
30. Thoroughly clean the sealing surfaces of the engine block and oil pan before installation.
31. 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!

30. On 1996-early 1998 A4 models:
1. Apply a light film of the recommended sealant on the front and rear contact surfaces and the seams of oil seal housings.
31. On late 1998-00 A4 and Passat models, if the upper oil pan was removed:
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. Immediately install the upper oil pan and tighten the oil pan-to-engine block fasteners to 44 inch lbs. (5 Nm).
3. Tighten oil pan-to-engine block bolts in 2 stages and using a crisscross pattern working from the center outward. Tighten as follows:
4. Oil pan-to-engine block M6 bolts, Stage 1, 44 inch lbs. (5 Nm).
5. Oil pan-to-engine block M6 bolts, Stage 2, 88 inch lbs. (10 Nm).
6. Tighten the oil pan-to-transmission M10 fasteners to 33 ft. lbs. (45 Nm)
7. 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:
8. Stage 1: 88 inch lbs. (10 Nm)
9. Stage 2: 11 ft. lbs. (15 Nm)
10. 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).
11. 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).
12. Tighten the oil pan-to-engine block M10 fasteners to 33 ft. lbs. (45 Nm)
32. Install the lower oil pan using a new gasket.

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)

33. Tighten oil pan-to-engine block bolts in 2 stages and using a crisscross pattern working from the center outward. Tighten as follows:
1. Oil pan-to-engine block M6 bolts, Stage 1, 44 inch lbs. (5 Nm).
2. Oil pan-to-engine block M6 bolts, Stage 2, 88 inch lbs. (10 Nm).
34. Install the torque support onto the rubber buffer for the torque support and tighten bolts to 18 ft. lbs. (25 Nm).
35. 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.
36. Check for any fluid leaks and repair as necessary.

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This details will help.

Thanks.

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