Oil Pan: Service and Repair
Oil pan, removing and installing
Special tools and equipment
^ Support bar 10-222 A
^ Lifting tackle 2024 A
^ Socket attachment 3249 or T10058
^ Workshop crane VAG 1202 A
^ Electric drill with plastic brush attachment
^ Protective goggles
Removing
^ Engine in vehicle.
^ Lock carrier in service position, Refer to Body and Frame, Radiator Support, Service and Repair
^ Unbolt noise insulation holder-arrow-.
^ Disconnect bottom left air hose from charge air cooler.
^ Remove engine cover -arrows-.
^ Mark positions of bolted connections -1- and locating sleeves -2underneath right and left engine mounts.
Note: Differing mounting holes are provided for different engine versions.
^ Remove nuts -1- underneath left and right engine mounts.
^ Place support bar 10-222 A on fender mounting flange.
^ Remove eye from lifting tackle 2024 A.
^ Insert pin -1- back into center hole of lifting tackle and secure it using cotter pin.
^ Attach pin of lifting tackle 2024 A to spindle of support bar 10-222 A.
^ Attach lifting tackle 2024 A to lifting eyes at front and rear of engine.
WARNING: Hook attachments and locating pins on lifting tackle must be secured with locking pins -arrows in illustration.
^ Pre-tension engine with spindle of engine support bar, do not lift.
^ Drain engine oil.
^ Unbolt turbocharger oil return line from oil pan.
^ Unplug connector from oil level sensor -arrow-.
Vehicles with automatic transmission:
Note: Observe rules for cleanliness when working on automatic transmission:
^ Remove bolt -3- and disconnect ATF lines from transmission.
Note: Ignore -1- and-2-.
^ Unbolt holder for ATF line from engine.
^ Move ATF lines clear to one side.
^ Unbolt torque reaction support -arrows-.
^ If installed, unclip operating rod for vehicle levelling sensor at bottom transverse link-arrow-.
^ Support subframe with workshop crane VAG 1202 A
^ First remove front bolts -2- and -3- from left and right subframe. Then remove bolts -1-.
Note: The subframe should be removed and lowered only at front, otherwise it will be necessary to check wheel alignment.
Vehicles with manual transmission:
^ Loosen nuts -arrow- on left transmission mount until it is flush with end of bolt (approximately 4 turns on thread).
Vehicles with automatic transmission:
^ Loosen rear bolt -2- on left transmission mount a few turns, remove and remove front bolt -1- on left transmission mount.
All models:
^ Loosen rear bolt -2- on right transmission mount a few turns, remove front bolt -1- on right transmission mount.
^ Lower subframe slowly using workshop crane VAG 1202 A
^ Run out workshop crane VAG 1202 A
^ Remove bolts securing transmission to oil pan.
^ Remove M10 bolts -arrows-.
^ Loosen bolts -1 to 18- in diagonal sequence.
^ Use T10058 for bolts 17 and 18.
Note: Remove both rear oil pan bolts -1- and -2- using socket attachment 3249 or T10058. On vehicles with manual transmission, do this by turning flywheel -3- until recess -arrow- is aligned with bolt.
^ Remove oil pan. If necessary, loosen by tapping lightly using a rubber hammer.
^ Remove baffle plate and carefully remove sealant remaining on cylinder block.
^ Remove remaining sealant from oil pan with rotating plastic brush or similar.
WARNING: Use safety goggles.
^ Clean sealing surfaces. They must be free of oil and grease.
Installing
Install in reverse order, paying attention to the following:
Note: The oil pan must be installed within 5 minutes of applying silicone sealant.
^ Cut off nozzle of tube at front marking (nozzle diameter approximately 3 mm).
Silicone sealant D 176 404 A2
Thickness of sealant bead: 2 to 3 mm
Note: The sealant bead must not be thicker than 3 mm, otherwise excess sealant can enter oil pan and obstruct filter screen in oil intake line.
^ Apply silicone sealant to clean sealing surface of oil pan, as illustrated. (Illustration shows position of sealant bead on cylinder block )
Note: Take extra care when applying bead of sealant around rear sealing flange -arrows in illustration-.
^ Install oil pan immediately and tighten bolts in sequence shown:
^ Pre-tighten bolts -1 to 18- to 5 Nm in diagonal sequence.
^ Tighten bolts securing oil pan to transmission to 45 Nm.
^ Tighten M10 bolts -arrows - to 40 Nm.
^ Tighten bolts -1 to 18- to 15 Nm in diagonal sequence.
Notes: Replace gaskets and sealing rings.
^ When installing oil pan -3- with engine removed, ensure that oil pan is positioned Rush with intermediate plate -1- at flywheel end, i.e. oil pan should protrude by dimension "a" = 0.8 mm from cylinder block -2-.
^ After installing oil pan, wait for approximately 30 minutes for sealant to dry before pouring in engine oil.
^ Support subframe with workshop crane VAG 1202 A.
^ Install subframe.
Vehicles with automatic transmission:
^ Secure ATF lines:
All models:
^ Install lock carrier.
^ Fill up with engine oil and check oil level.
Vehicles with automatic transmission:
^ Check ATF level:
Tightening torques