Removal and Replacement
Oil pan, removing and installing
Special tools, testers and auxiliary items required
^ Engine support bridge 10-222A with feet 10-222 A/1
^ Lifting tackle 2024A
^ SW 10 hex ball socket 3185
^ Hex ball socket T10058
^ Shop crane V.A.G 1202A
^ Torque wrench V.A.G 1331
^ Hand drill with plastic brush attachment
^ Silicone sealant D 176 404 A2
Removing
- Bring lock carrier into service position. [1][2]Procedures
- Drain engine oil.
- Unbolt stop - 1 - - arrows -.
- Unclip lower section - 1 - of starter wire mount - arrows -.
- Disconnect turbocharger oil return line at oil pan.
Vehicles with automatic transmission
- Remove bracket - 1 - for ATF lines - arrows -.
Continued for all vehicles
- Disconnect connector from Oil Level Thermal Sensor G266.
- Mark installed position of threaded connection - 1 - and lower locating sleeve - 2 - on left and right engine mounts.
- Unbolt both lower engine mounts.
- Install engine support bridge 10-222A as shown.
- Remove eyelet for Engine Sling 2024A.
- Insert bolt - 1 - in the center bore of engine sling again and secure with a cotter pin.
- Hook engine sling bolt 2024A into engine support bridge spindle 10-222A.
- Hook engine sling 2024A into sling clamps at front and rear of engine.
CAUTION! Lifting hooks and alignment pins on the engine sling must be secured with securing pins - arrows - in the illustration.
- Lift engine with engine support bridge spindle as far as possible or until T-piece of the crankcase ventilation lies against bulkhead (approx. 20 mm).
- Support subframe with workshop crane V.A.G 1202A.
- First remove front bolts - 2 - and - 3 - from left and right sides of subframe. Then remove bolts - 4 -.
Note: To avoid performing a wheel alignment, the subframe must only be loosened and lowered at the front end.
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
- Loosen rear bolt - 2 - for left transmission mount a few turns and remove front bolt - 1 - for left transmission mount.
Continued for all vehicles
- Loosen rear bolt - 2 - of right-hand transmission mount a few turns. Remove front bolt - 1 - of right-hand transmission mount.
- Lower subframe slowly with shop crane.
- Remove shop crane and swing stabilizer bar downward.
- Remove oil pan.
Note:
^ Use SW 10 flex wrench 3185 to loosen and tighten the rear inner oil pan bolts, and use hex ball socket T10058 to remove and drive in bolts.
^ Both rear inner oil pan bolts can be reached through the notches in the flywheel - arrow - on vehicles with manual transmission. To do this, turn the flywheel accordingly.
- Remove oil pan. Loosen oil pan with light blows of a rubber mallet if necessary.
- To swing the oil pan over the subframe, swing rear of oil pan to left and push left side of subframe downward somewhat.
- Remove sealant residue from cylinder block with a flat scraper.
- Remove sealant residue from pan with a rotating brush, e.g. a hand drill with a plastic brush attachment (wear eye protection).
- 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.
^ Note the expiration date of the sealing compound.
^ The oil pan must be installed and fastened within 5 minutes after application of silicone sealant.
- Cut tube nozzle at front marking (nozzle dia. approx. 3 mm).
- Apply silicone sealant D 176 404 A2, as shown, to clean oil pan sealing surface. Sealing compound bead must be:
^ 2 to 3 mm thick
^ and run on inside of bolt holes - arrows -
Note: The sealing compound bead must not be thicker, otherwise excess sealing compound may enter the oil pan and block the oil suction pipe strainer.
- Apply silicone sealant D 176 404 A2 as illustrated to clean sealing surface of oil pan.
Note: Apply the sealant at the rear area of the sealing flange very carefully. There are two holes in the cylinder block at the areas identified with - arrows -.
- Before installing oil pan, insert the right vertical bolt M10 into oil pan.
- Install oil pan immediately and tighten all bolts lightly.
- Tighten the M7 oil pan bolts in a diagonal sequence to 15 Nm.
- Tighten the M10 oil pan/cylinder block bolts to 45 Nm.
- Tighten oil pan/transmission bolts to 45 Nm.
Note: After installing oil pan, allow sealant to harden for approx. 30 minutes before refilling engine oil.
The rest of assembly is basically a reverse of the disassembling sequence.
- Install subframe.
Tightening torques:
