Oil Pan: Service and Repair

Oil pan, removing and installing





Special tools, testers and auxiliary items required
^ Jointed wrench 3185
^ Socket T10058
^ Torque wrench V.A.G 1331
^ Hand drill with plastic brush
^ Protective glasses
^ Flat scraper
^ Silicone sealant D 176 404 A2
^ Locking fluid D 000 600 A2

Removing
- Remove middle and right side sound insulation.

Engines with oil pan guard





- Remove bolts - 2 - and take sleeves - 3 - off front and rear parts of oil pan guard.
- Press spreader pin out upward and remove spreader rivet - 4 -.
- Remove oil pan guard - 1 -.

Engines with long-life service





- Disconnect 3-pin connector from Oil level thermal sensor -G266-.

Continued for all engines
- Drain engine oil.

Note:
^ Please observe disposal instructions!

- Unscrew oil pan bolts.

Note:
^ Loosen oil pan bolts with jointed wrench 3185 and unscrew with socket T10058.

- Remove oil pan. Loosen oil pan with light blows of a rubber headed hammer if necessary.
- Remove sealant residue on cylinder block with a flat scraper.





- Remove sealant residue on oil pan with a rotating brush, e.g. a hand drill with a plastic brush (wear eye protection).
- Clean sealing surfaces. They must be free of oil and grease.

Installing

Note:
^ Observe the use-by date of the sealing compound.
^ The oil pan must be installed within 5 minutes of applying silicone sealing compound.





- Cut off tube nozzle at forward marking (nozzle diameter approx. 3 mm).
- Apply silicone sealing compound, as shown, to clean oil pan sealing surface.

Sealant bead must be:
^ 2 to 3 mm thick for engines with one-piece oil pan
^ 1 to 2 mm thick for engines with two-piece oil pan
^ 4 Run bead along inner side of bolt holes - arrows -.

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





- In area of - arrows -, sealant bead must be applied with particular care (illustration shows position of sealant bead at cylinder block).
- Install oil pan immediately and tighten all oil pan bolts as follows:
1. Tighten all bolts for oil pan to cylinder block only very lightly using alternate and diagonal sequence.
2. Lightly tighten three bolts securing oil pan to transmission.
3. Retighten all bolts for oil pan to cylinder block lightly using alternate and diagonal sequence.
4. Tighten all bolts for oil pan to cylinder block to 15 Nm using alternate and diagonal sequence.
5. Tighten three oil pan to transmission bolts to 45 Nm.

Note:
^ When installing the oil pan with the engine out of the vehicle, ensure that the oil pan is flush with the cylinder block at the flywheel end.
^ Let sealing compound dry for approx. 30 minutes after installing the oil pan. Only then fill the engine with oil.

Engines with oil pan guard

Note:
^ Check condition of rubber bushes in cylinder block (for mounting spreader rivets) before installing oil pan guard.
^ Before bolts are reinstalled, clean threads and apply locking fluid D 000 600 A2.





- Insert spreader pin flush with spreader rivet - 4 - and install in oil pan guard - 1 -.
- Tighten bolts - 2 - at front and rear of oil pan to 37 Nm.

Continued for all engines
The rest of the assembly is basically a reverse of the disassembly sequence.