Oil Pan: Service and Repair

Oil sump, removing and installing
Removing lower sump
Removing upper sump

Special tools and equipment





^ VAG 1331 Torque wrench (5...50 Nm)
^ D 176 404 A2 Silicone sealant
^ Hand drill with plastic brush
^ Protective glasses
^ Flat scraper

Removing
^ Remove sound insulation.
^ Remove air conditioning line bracket on upper sump.
^ Drain engine oil.

Note: Observe disposal regulations!

^ Remove lower sump.
^ Loosen sump with light blows of a rubber headed hammer if necessary.





^ Remove sealant residue on upper sump with a flat scraper.
^ Remove sealant residue on sump with a rotating brush, e.g. a hand drill with a plastic brush (wear eye protection).
^ Clean sealing surface, must be free of oil and grease.

Removing upper sump
Special tools and equipment





^ 10-222 A Support bracket with legs 10-222 A/1
^ 10-222A/2 Additional hooks
^ 10-222A/12 Shackle
^ 10-222A/17Spacertube
^ T40016 Transport bracket
^ VAG 1202 A Workshop crane





^ VAG 1331 Torque wrench (5...50 Nm)

Removing
^ Remove sound insulation.
^ Remove ribbed belt.





^ Mark installation position of threaded connection -1- and lower locating sleeve -2- on left and right engine mountings.
^ Disconnect vacuum lines -3- at Left Electro-Hydraulic Engine Mount Solenoid Valve -N144-/Right Electro-Hydraulic Engine Mount Solenoid Valve -N145-.
^ Disconnect both lower engine mountings.





^ Secure T40016 transport bracket to rear left of cylinder head with securing screw-1-.
Tightening torque: 25 Nm





^ Install engine support bracket 10-222A with additional hooks 10-222A/2 and shackle 10-222A/12 as illustrated.
^ Lift engine as far as possible via spindle of support.
^ Remove torque bracket.





^ Support subframe with workshop crane 1202 A





^ Remove subframe front bolts -1- on left and right-hand sides. Then remove bolts -3-.

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





^ Loosen rear bolt -2- of left-hand transmission mounting a few turns. Remove front bolt -1- of left-hand transmission mounting.





^ Loosen rear right transmission mounting rear bolt -2- several turns, remove right transmission mounting front bolt -1-.





^ Lower subframe slowly with workshop crane.
^ Remove workshop crane, swing stabilizer bar down.
^ Remove retainers for coolant and refrigerant lines on upper sump.
^ Remove oil pump oil lines.
^ Remove crankcase breather oil return line
^ Remove power steering pump from bracket and remove bracket.
^ Remove oil return lines.
^ Remove upper sump.

Installing
^ Clean sealing surface. Surface must be free of oil and grease.

Installing upper sump
^ Install upper sump with a new gasket.








^ Tighten bolts in sequence shown and observe different lengths of bolts:
^ Tighten sump/transmission bolts to 40 Nm.
The rest of the assembly is basically a reverse of the disassembling sequence.
^ Install subframe.
^ Install ribbed belt.





Tightening torques

Installing lower sump

Note:
^ Note the use by date of the sealant.
^ The sump must be installed within 5 minutes of applying the silicone sealing compound.





^ Cut off tube nozzle at forward marking (approximately 3 mm diameter).
^ Apply silicone sealing compound, as shown, to clean sump sealing surface. Sealing compound bead must be:
^ 2...3 mm thick
^ and run on inside of bolt holes (arrows)

Note: The sealing compound bead must not be thicker, otherwise excess sealing compound will enter the sump and may block the oil suction pipe strainer.

^ Install sump immediately and tighten all sump bolts lightly.
^ Tighten sump bolts to 8 Nm.
^ Tighten coolant / refrigerant line retainers on upper sump to 8 Nm.

Note: After installing the sump the sealant must be allowed to dry for approximately 30 minutes before engine oil is replenished.

Remaining assembly is a reverse of the disassembling sequence.