Oil Pan: Service and Repair
Oil pan, removing and installing
Special tools, testers and auxiliary items required
^ Engine support bridge 10-222A
^ Shop crane V.A.G 1202 A
^ Torque wrench (5 to 50 Nm) V.A.G 1331
^ Hex ball socket T10058
Not illustrated:
Special tools, testers and auxiliary items required
^ Hand drill with plastic brush attachment
^ Silicone sealant D 176 404 A2
^ Flat scraper
^ Protective glasses
Removing
- Bring lock carrier into service position. [1][2]Procedures
- Drain engine oil.
- Cut through cable ties - arrows -, open starter harness retainer and take harness off.
- Remove limit stop - 1 - - arrows -.
Vehicles with automatic transmission
- Remove bolts - arrows - from ATF line bracket - 1 - on oil pan.
Continued for all vehicles
- If equipped, disconnect connect connector from Oil Level Thermal Sensor -G266-.
- Mark installed position of threaded connections - 1 - and locating sleeves - 2 - on lower left and right engine mounts.
- Remove both lower engine mounts.
- Remove Motor for intake flap -V157-.
- Set engine support bridge 10-222A in place as shown and connect to engine in installed position.
- Lightly tension engine with spindles of engine support bridge.
- Support subframe with workshop crane V.A.G 1202 A.
Note: To avoid having to perform a wheel alignment, the subframe must only be loosened or lowered at the front end.
- Remove front bolts - 2 - and - 3 - from left and right sides of subframe. Then remove bolts - 4 -.
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
- Unscrew rear bolt - 2 - for left transmission mount several turns and remove front bolt - 1 - for left transmission mount.
Continued for all vehicles
- Unscrew rear bolt - 2 - for right transmission mount several turns and remove front bolt - 1 - for right transmission mount.
- Slowly lower subframe with workshop crane.
- Roll out workshop crane, and swing stabilizer bar downward.
Note: To loosen and tighten both rear oil pan bolts use the hex ball socket T0058.
- Loosen oil pan with light blows of a rubber headed hammer if necessary.
- Remove oil pan.
- Remove sealant residue from cylinder block with a flat scraper.
- Remove remaining sealant at oil pan using a rotating brush, e.g. a drill with plastic brush attachment (wear protective glasses).
- Clean sealing surfaces. Sealing surfaces must be free of oil and grease.
Installing
Note:
^ When installing the oil pan on a removed engine, make sure that the flywheel end of the oil pan is aligned flush with the intermediate plate, therefore the oil pan must extend beyond the cylinder block by 0.8 mm.
^ When installing the oil pan on an installed engine, the oil pan must be flush with the transmission flange.
^ Note the expiration date of the sealing compound.
^ The oil pan must be installed within 5 minutes after application of the silicone sealant.
- Cut off nozzle on tube of sealant at front mark (diameter of nozzle approx. 3 mm).
- Apply silicone sealing compound, as shown, to clean oil pan sealing surface. Sealing compound bead must be:
^ 2...3 mm thick.
^ Run around 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 pipe strainer.
- Apply silicone sealing compound bead as illustrated to clean sealing surface of cylinder block. (The ill. shows the location of the sealant bead on the cylinder block.)
- Before installing oil pan, insert bolts M10 at a right angle into oil pan.
- Install oil pan immediately and tighten all oil pan bolts lightly.
- Lightly fasten oil pan/transmission bolts.
- Tighten oil pan bolts in a diagonal sequence to 15 Nm.
- Tighten M10 bolts for oil pan/cylinder block to 40 Nm.
- Tighten bolts for oil pan/transmission to 45 Nm.
Note: After installing oil pan, allow sealant to dry for approx. 30 minutes. Only after this time may the engine be filled with oil.
The rest of the assembly is basically a reverse of the disassembly sequence.