Oil Pan Upper Section

Oil Pan Upper Section

Special tools, testers and auxiliary items required

• Valve assembly tool (2036)

• Torque Wrench (V.A.G 1331)

• Securing pin (T10115)

• 3 bolts M8x20, 3 washers

• Hand drill with plastic brush attachment

• Protective eyewear

• Silicone sealant (D 174 003 A2)

Removing

- Loosen camshaft gears => [ Valve Timing, Adjusting ] Valve Timing, Adjusting, adjusting valve timing.

- Remove control housing cover => [ Control Housing Cover ] Service and Repair.

- Tension chain tensioner - 1 - and secure it using drift (T10115).





- Remove glide track - 2 -.

- Remove sealing flange for crankshaft ribbed belt side => [ Crankshaft Sealing Flange, Belt Pulley Side ] Service and Repair.

- Remove lower section of oil pan => [ Oil Pan Lower Section ] Oil Pan Lower Section.

- Remove bolts - 2 - and - 4 - and remove intake line.





- Remove bolts - 1 -.

- Press off upper section of oil pan from cylinder block at designated points using a suitable screwdriver - A -.





B Bearing cap 6 for crankshaft
C Bearing cap 1 for crankshaft

Installing

CAUTION!
To prevent injuries from shavings, wear protective goggles and protective clothing.

- Remove remainder of sealant from upper section of oil pan and cylinder block e.g. using a rotating plastic brush.

CAUTION!
Make sure that no sealant residue enters the engine.

- Clean sealing surfaces so they are completely free of any oil or grease.

- Cut tube nozzle at front marking (dia. of nozzle approximately 1 mm).





Note shelf-life date.

• The upper section of oil pan must be installed within 5 minutes after application of sealant.

- Apply sealant bead - 1 -, - 2 - and - 3 - as depicted on to clean sealing surface of upper section of oil pan.





• The sealant bead must be 1.5 to 2.0 mm thick.

- Place upper section of oil pan on to cylinder block and align it on transmission side.

- Install 2 bolts each at front and rear hand-tight.

- Wipe off excess sealant in area of - arrows -.





- Loosen bolts again slightly.

- Secure plates (2036/1) from valve assembly tool (2036) on cylinder block as depicted.

- Press upper section of oil pan firmly on to plates (2036/1) and tighten bolts again hand-tight.

- Install remaining bolts and tighten by hand.

Make sure that upper section of oil pan makes contact on plates (2036/1).

- Tighten all bolts in diagonal sequence from inside working toward outside.

- Insert new seal - 5 - into oil pump - 6 -.





- Bolt intake line - 1 - with bolts - 2 - and - 3 - as well as bracket - 4 -.

- Install glide track - 2 -, relieve tension on chain tensioner - 1 - and pull out drift (T10115 ).





- Adjust valve timing => [ Valve Timing, Adjusting ] Valve Timing, Adjusting.

The rest of installation follows the reverse of the removal procedures. When doing this note the following:

• After installing oil pan, allow sealant to dry for approximately 30 minutes. Only after then may the engine oil be replenished.

• Remove locking pin (T40069) from cylinder block at rear and screw in plug.

• Fill with coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.

Tightening specifications: