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.
- Unbolt sound insulation holder (arrow).
- Disconnect lower left air hose from charge air cooler.
- Remove engine cover (arrows).
- Mark positions of bolted connections -1- and locating sleeves -2- underneath 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).
- Pre-tension engine with spindle of engine support bar, do not lift.
- Drain engine oil.
- Unbolt turbocharger oil return line from oil pan.
- Disconnect connector from oil level sensor (arrow).
Vehicles with automatic transmission
Note: Observe the rules for cleanliness when working on the automatic transmission:
- Remove bolt -3- and disconnect ATF lines from transmission.
Note: Please ignore items -1- and -2- in the illustration.
- 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 leveling sensor at lower 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 the 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.
- Roll 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.
Note: 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: Wear 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).
- 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.
Note:
^ Replace gaskets and sealing rings.
^ When installing oil pan -3- with engine removed, ensure that oil pan is positioned flush 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 engine with oil and check oil level.
Vehicles with automatic transmission
- Check ATF level:
Tightening torques
Tightening torques:
