Oil Pan, Upper Section, Removing and Installing

Oil Pan, Upper Section, Removing and Installing





Special tools, testers and auxiliary items required

• Assembly tool (T10118)

• Testing tool for brake wear (VW 136)

• Torque Wrench (V.A.G 1331)

• Silicone sealant (D 174 003 A2)

Removing

- Remove the transmission.

- Remove the oil pump => [ Oil Pump, Removing and Installing ] Service and Repair.

- Remove the transmission-side sealing flange => [ Transmission-Side Sealing Flange, Removing and Installing ] Transmission-Side Sealing Flange, Removing and Installing.

- Remove the front right wheel housing liner => Body

Exterior 66 Wheel Housing liner.

- Remove bolts - arrows -.





- Remove the air guide pipe by lifting the clamps - 1 and 2 -.

- Remove the bolt - 1) -





- Disconnect the wiring bracket mount next to the After-Run Coolant Pump (V51) from the upper part of the oil pan.

CAUTION!
To prevent leaks in the future, do not ben the lower timing chain cover and do not reach between the mounting points.

- Remove the bolts - 14 and 15 -.





DANGER!
Risk of injury. When removing the oil pan upper section, the chain tensioner spring for the oil pump motor will jump from the oil pan upper section to the lower timing chain cover. When removing the oil pan upper section, do not reach between the section and the lower timing chain cover.

- Remove the bolts - 1 through 14 - and the upper section of the oil pan. When loosening, start on the transmission side.





Installing

• Tightening specifications => [ Oil Pan, Oil Pump, Assembly Overview ] Oil Pan, Oil Pump, Assembly Overview

• Note the expiration date of the silicone sealant.

• The oil pan (upper part) must be installed within 5 minutes after application of silicone sealant.

- Mount the Assembly Tool (T10118) and pull the spring in the chain tensioner for the oil pump drive in the direction of the - arrow -.





- Secure the spring by inserting the Gauge (VW 136) into the 2.2 mm hole, as shown in the illustration.

- Remove sealant residue from engine block with a flat scraper.

CAUTION!
Wear safety glasses.

- Remove the remaining sealant on the upper part of the oil an on the lower timing chain cover, e.g, with a rotating plastic brush.





• See if the timing chain cover is deformed. Then mount the top section of the oil pan without any sealant and check the gap between the cover and the top section. If a deformation is found, do not try to re-align it, replace the cover.

- Clean sealing surfaces, must be free of oil and grease.

- Make sure the oil passages in the upper part of the oil pan and in the cylinder crankcase clean.

- Cut tube nozzle at front marking (dia. of nozzle approximately 3 mm).





- Apply the silicone sealant (D 174 003 A2) on the clean sealing surface of the upper oil pan section as shown - arrows -.





• Thickness of sealant bead: 2 to 3 mm

• The oil pan (upper part) must be installed within 5 minutes after application of silicone sealant.

• The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

• On the transmission side, the upper part of the oil pan and the crankcase must align.

- Immediately mount the upper part of the oil pan and tighten the screws - 1 through 14 - in two steps as follows:





- Tighten the bolts to 15 Nm.

- Tighten the bolts an additional 90°.

- Install the bolts - 14 and 15 -. Tightening specifications => [ (Item 12) Bolt ] Timing Chain Covers, Assembly Overview





The rest of the assembly is basically a reverse of the disassembling sequence.