Oil Pan, Upper Section

Oil Pan, Upper Section

Special tools, testers and auxiliary items required





^ Engine support bridge 10-222 A with Bracket for engine 10-222 A/1 and Engine support adapter 10-222 A/3





^ Shop crane V.A.G 1202/A
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Hand drill with plastic brush attachment
^ Flat scraper
^ Protective glasses
^ Protective gloves
^ Cable tie
^ Silicone sealant D 176 404 A2

Removing

- Disconnect battery.





- Install engine support bridge 10-222 A as shown.
- Hook engine to engine support bridge 10-222 A and engine support adapter 10-222 A/3 at front and rear lifting eyelets and pre-tension slightly.
- Slightly pre-tension engine using engine support bridge 10-222 A spindles.





- Remove bolt for oil dip stick guide tube from cylinder head - arrow - and remove guide tube upward.
- Drain coolant.
- Bring lock carrier into service position. [1][2]Procedures
- Remove torque support from upper part of oil pan at front.
- Remove coolant pipe on front of engine from oil pan.
- Disconnect coolant lines from oil cooler under oil filter.
- Disconnect connector from oil pressure switch.





- Cut cable ties - arrows -, open bracket for starter wiring and remove wiring.
- Removing starter.





- Mark installed position of threaded connection - 1 - and lower locating sleeve - 2 - on left and right engine mounts.
- Remove nuts - 1 - on left and right.





- Support subframe with workshop crane V.A.G 1202/A.





- First remove front bolts - 2 - and - 3 - from left and right sides of subframe. Then remove bolts - 4 -.

Note: To avoid having to perform a wheel alignment, the subframe must only be loosened and lowered at the front end.

Vehicles with manual transmission





- Loosen left transmission mount nut - arrow - until it is aligned with lower edge of bolt (approx. 4 turns).

Vehicles with automatic transmission





- Loosen rear bolt - 2 - for left transmission mount a few turns and remove front bolt - 1 - for left transmission mount.

Continued for all vehicles





- Loosen rear bolt - 2 - of right transmission mount a few turns. Remove front bolt - 1 - of right transmission mount.





- Lower subframe slowly with workshop crane V.A.G 1202/A.
- Remove workshop crane V.A.G 1202/A, swing stabilizer bar down.
- Remove lower part of oil pan.

Engines with oil pump with chain drive
- Remove oil pump.

Continued for all engines
- Remove engine/transmission bolts in area of upper part of oil pan.





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

Installing
Installation is performed in reverse order of removal. Note the following.

Note: Always replace self-locking nuts, gaskets and seals.

Upper part of oil pan with solid gasket
- Before installing, clean sealing surfaces of upper part of oil pan.





- Set upper part of oil pan in place and fasten bolts - 1 - alternating diagonally to 5 Nm.
- Tighten only oil pan/transmission bolts to 45 Nm.
- Tighten oil pan/cylinder block bolts alternating diagonally to 10 Nm.






Upper part of oil pan with silicon gasket

CAUTION! Wear safety glasses.

- Remove residual gasket material from upper part of oil pan and cylinder block e.g. with a drill with plastic brush attachment.





- Clean sealing surfaces of oil and grease.

Note: The upper part of oil pan must be installed within 5 minutes after application of silicone sealant.





- Cut tube nozzle at front marking (nozzle diameter approx. 3 mm).





- Apply a bead of silicone sealant as illustrated to clean sealing surface of upper part of oil pan.
- Thickness of sealant bead - arrows -: 2 to 3 mm

Note:
^ The sealant bead may not be thicker than 3 mm, otherwise excess sealant could enter the oil pan and clog the oil intake tube.
^ Apply the bead of sealant at the rear area of the sealing flange very carefully.





- Set upper part of oil pan in place (2 technicians necessary) and fasten oil pan/cylinder block bolts - 1 - and - 2 - alternating diagonally to 5 Nm.
- Tighten only oil pan/transmission bolts to 45 Nm.
- Tighten oil pan/cylinder block bolts alternating diagonally.
^ Tightening torque for M6 bolts: 10 Nm
^ Tightening torque for M7 bolts: 15 Nm
^ Tightening torque for M8 bolts: 22 Nm





Note: After installing upper part of oil pan, allow sealant to dry for approx. 30 minutes. Only then may the engine be filled with oil.

Engines with oil pump with chain drive
- Install oil pump.

Continued for all engines
The rest of the assembly is basically a reverse of the disassembling sequence.
- Install lower part of oil pan.
- Install subframe.