Oil Pan: Service and Repair
Oil pan, removing and installing
Special tools and equipment
- Engine support bracket 10-222A with legs 10-222A/1
- Workshop crane VAG 1202 A or equivalent
- Hand drill with plastic brush
- Silicone sealant D 176 404 A2
- Punch, 5 mm diameter
- Cable tie
Removing
- Bring lock carrier into service position. Lock Carrier And Front Bumper Reinforcement, Moving to Service Position
- Drain engine oil.
- Mark toothed belt direction of rotation.
- Remove ribbed belt. [1][2]Procedures
- Remove A/C compressor ribbed belt tensioning roller complete.
- Take off A/C compressor ribbed belt.
- Secure viscous fan coupling belt pulley with a punch (5 mm diameter) -1-.
- Remove viscous fan coupling securing bolt (with 8 mm hex key -2-) and remove viscous fan coupling with belt pulley.
- Unbolt torque rod bracket (arrows).
- Cut through cable ties (arrows), open retainer for starter wiring and take out wiring.
- Remove support between oil pan and intake manifold
- Unbolt oil return line from turbocharger.
- Disconnect left upper engine mounting.
- Mark installation position of threaded connection -1- and lower locating sleeve -2- on left and right engine mountings.
- Disconnect both lower engine mountings.
- Slide lock carrier again to rear and bolt top on.
- Attach lifting device 10-222A as shown.
- Support engine at front lifting eye with lifting device.
- Lift engine with spindle of lifting device until air hose to throttle valve module touches bulkhead.
- Take out left engine mounting.
- Support subframe with workshop crane 1202 A.
- First remove front subframe bolts -2 and -3- on left and right-hand sides. Then remove bolts -4-.
Note: To avoid measuring wheel alignment, the subframe must only be loosened or lowered at the front end.
- Loosen rear right transmission mounting rear bolt -2- several turns, remove right transmission mounting front bolt -1-.
- Loosen nut for left-hand transmission mounting (arrow) until it aligns with lower edge of bolt (turned approx. 4 threads).
- Lower subframe slowly with workshop crane.
- Remove workshop crane, swing stabilizer bar down.
- Remove oil pan, it may be necessary to release sump by tapping lightly with a rubber head hammer.
Note: It may be necessary to release the oil pan by tapping it lightly with a rubber mallet.
Vehicles without solid gasket
- Remove sealant residue on cylinder block with a flat scraper.
- Remove sealant residue on oil pan with a rotating brush, e.g. hand drill with a plastic brush (wear protective glasses).
- Clean sealing surface so that it is free of oil and grease.
Installing
- Install oil pan with solid type gasket.
Vehicles without solid gasket
Note: Note the "use by" date of the sealant.
The oil pan must be installed within 5 minutes of applying silicone sealing compound.
- Cut-off tube nozzle at forward marking (nozzle approx. 3 mm diameter).
- Apply silicone sealing compound, as shown, to clean oil pan sealing surface.
Sealing compound bead must be:
2 to 3 mm thick
applied on inside of bolt holes (arrows)
Note: The sealing compound bead must not be thicker, otherwise excess sealing compound will enter the oil pan and may block the oil suction line strainer.
- Apply silicone sealing bead as shown to clean sealing surface of oil pan. (illustration shows position of sealant bead on cylinder block).
- Install oil pan immediately and tighten all oil pan bolts lightly.
Note: After installing the oil pan the sealant must be allowed to dry for approx. 30 minutes before the engine is filled with oil.
Continued for all vehicles
- Tighten oil pan bolts to 15 Nm
Note: The remaining assembly is basically a reverse of the disassembly sequence.
- Tighten bolts securing oil pan to transmission to 45 Nm.
- Tighten M10 bolts securing oil pan to cylinder block to 45 Nm.
Tightening torques
Engine mounting to subframe 25 Nm
Engine mounting to engine support 25 Nm
Torque rod bracket to engine 25 Nm
Transmission support to transmission mounting M10 40 Nm
Transmission mounting to subframe M8 25 Nm
Intake manifold bracket 25 Nm