Upper Oil Pan

Upper Oil Pan

Special tools, testers and auxiliary items required

• Adapter Plates (2036/1)

• Torque Wrench (5-50 nm) (V.A.G 1331)

• Locking Pin (T10115)

• 3 M8 x 20 bolts and 3 washers

• Hand drill with plastic brush attachment

• Protective eyewear

• Silicone sealant (D 174 003 A2)

Removing

- Loosen the camshaft sprocket and adjuster. Refer to => [ Valve Timing, Adjusting ] Adjustments.

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

- Tension the oil pump drive chain tensioner - 1 - and secure it using the (T10115).





- Remove the guide rail - 2 -.

- Remove the sealing flange. Refer to => [ Sealing Flange, Belt Pulley Side ] Sealing Flange, Belt Pulley Side.

- Remove the lower oil pan. Refer to => [ Lower Oil Pan ] Lower Oil Pan.

- Remove the bolts - 2 and 4 - and the oil intake pipe.





- Remove the bolts - 1 -.

- Pry the upper oil pan off the cylinder block using a suitable screwdriver - A - at the areas shown.





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

Installing

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

- Remove sealant residue from the cylinder block using a rotating plastic brush.

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

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

- Cut the tube nozzle at the front mark (nozzle diameter approximately 1 mm).





Note shelf life date.

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

- Apply sealant beads - 1 -, - 2 - and - 3 - to the clean sealing surfaces on the upper oil pan as shown.





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

- Position the upper oil pan to the cylinder block and align it on the transmission side.

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

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





- Loosen the bolts again slightly.

- Install the (2036/1) from the (2036) to the cylinder block as shown.

- Press the upper oil pan tightly against the (2036/1) and tighten the bolts by hand.

- Install the remaining bolts and tighten by hand.

Make sure that upper oil pan makes contact with the (2036/1 ).

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

- Instal a new seal - 5 - into the oil pump - 6 -.





- Install the oil intake pipe - 1 - and the bracket - 4 - with the bolts - 2 and 3 -.

- Install the guide rail - 2 -, relieve the tension on the oil pump drive chain tensioner - 1 - and pull out the (T10115).





- Adjust the valve timing. Refer to => [ Valve Timing, Adjusting ] Adjustments.

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

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

• Remove the (T40069) from the rear of the cylinder block and install the locking bolt. Tighten the locking bolt to 45 Nm.

• Fill with coolant. Refer to => [ Draining and Filling ] Draining and Filling.

Tightening Specification