Oil Pan: Service and Repair

Oil Pan, Removing and Installing






Special tools, testers and auxiliary items required

• Flex wrench (3185)

• Multipoint socket (T10058)

• Torque wrench (V.A.G 1331)

• Hand drill with plastic brush attachment

• Sealant (D 176 404 A2)

• Sealant (AMV 176 501)

• The oil pan consists of 2 sections (upper section and lower section) The complete oil pan is removed from the cylinder block.

• Install the oil pan lower section only if only the oil pan lower section was removed.

Perform the following:

Removing

- Remove the noise insulation.

- Drain engine oil.

• Observe disposal regulations!

- Remove the oil pan bolts.

• Loosen the oil pan bolts using the jointed socket (3185) and the hex ball socket (T10058).

- Remove oil pan, if necessary loosen by applying light strikes with a rubber hammer.

- Remove any sealant residue on the cylinder block using a flat blade scraper.


To prevent injuries, wear protective eyewear and protective clothing.

- Remove the sealant residue on the oil pan using a rotating brush such as a drill with a plastic brush attachment.






- Clean the sealing surfaces.

• They must be free of oil and grease.

Installing

• Be sure to check the expiration date of the sealant.

• The oil pan must be installed within 5 minutes of being applied with sealant.

- Cut the tube nozzle at the front marking (nozzle diameter: approximately 1 mm).






- Apply sealant (D 176 404 A2) on the cleaned sealing surface on the oil pan as illustrated.

• The sealant bead must be 1 to 2 mm thick.

• It must around the inside of the holes for the bolts - arrows -.

• The sealant bead must not be thicker. The extra sealant will get into the oil pan and can clog up the intake line for the oil pump.

- Be especially careful when applying the bead of sealant near - arrows -.






• When installing the oil pan to a removed engine, make sure that the oil pan is positioned flush with the cylinder block on the flywheel side.

• After installing oil pan, allow sealant to dry for approximately 30 minutes. Only after then may the engine oil be replenished.

- Mount the oil pan immediately and tighten the bolts as follows:

1. Tighten all bolts of oil pan/cylinder block only very lightly in diagonal sequence.

2. Lightly tighten bolts of oil pan/transmission.

3. Tighten further all bolts of oil pan/cylinder block lightly in diagonal sequence.

4. Tighten the oil pan/transmission bolts to 45 Nm.

5. Tighten all oil pan/cylinder block bolts in a diagonal sequence to 15 Nm.


If the oil pan lower section was removed:


To prevent injuries, wear protective eyewear and protective clothing.

- Remove the sealant residue on the oil pan upper and lower sections using a rotating brush such as a drill with a plastic brush attachment.

- Clean the sealing surfaces.

• Sealing surfaces must be completely free of oil and grease.

• Be sure to check the expiration date of the sealant.

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

- Apply sealant (AMV 176 501) to the sealing surface on the oil pan's clean sealing surface, as illustrated.






• The sealant bead - A - must be 1 to 2 mm thick.

• It must around the inside of the holes for the bolts - arrows -.

• The sealant bead must not be thicker. The extra sealant will get into the oil pan and can clog up the intake line for the oil pump.

- Install the oil pan lower section immediately and tighten the bolts as follows:

1. Tighten all the bolts slightly.

2. Tighten all the bolts in a diagonal sequence to 22 Nm.


Assemble in reverse order of disassembly.