Oil Pan: Service and Repair

Oil Pan

Special tools, testers and auxiliary items required

• T Bar and Socket 10 mm (3185)

• Hex Ball Socket (T10058)

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

• Flat Scraper

• Silicone Sealant (D 176 404 A2)

Removing

- Remove the noise insulation.

- Drain the engine oil.

• Observe disposal regulations!

- Remove the charge air pipe bolts - arrows -.






- Remove the bolts - 1 and 2 -.






- Remove the oil return line bolts - arrows -.






- Disconnect the connector - 1 - for the oil level thermal sensor (G266).

- Remove the transmission to oil pan bolts - arrows -.






- Loosen the oil pan bolts on the flywheel side using the T bar and socket 10 mm (3185) and remove them using the hex ball socket (T10058).

- Remove the remaining bolts and remove the oil pan. If necessary loosen it by applying light strikes with a rubber mallet.

- Remove any sealant residue on the cylinder block using a flat blade scraper.

- Use a rotating plastic brush to remove any remaining sealant on the oil pan.






Installing

• Note the expiration date of the sealant.

• The oil pan must be installed and tightened immediately after application of the sealant.

- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 0.12 in).






- Apply silicone sealant to the clean oil pan sealing surfaces as shown. The sealant bead must be:

• 2 to 0.3 mm thick

• Run around inside of the bolt holes - arrows -

• The sealant bead must not be thicker. The extra sealant will get into the oil pan and can clog the intake pipe strainer for the oil pump.

• With the transmission removed, the oil pan must seat flush with the cylinder block.

• With the transmission installed, the oil pan must make contact on the transmission.

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

- Immediately install the oil pan and the bolts as follows:

1 Tighten all the oil pan to cylinder block bolts lightly in a diagonal sequence.
2 Tighten the oil pan to transmission lightly.
3 Tighten all the oil pan to cylinder block bolts lightly in a diagonal sequence.
4 Tighten the oil pan to transmission bolts to 40 Nm.
5 Tighten all the oil pan to cylinder block bolts in a diagonal sequence to 15 Nm.

Further installation is in the reverse order of removal.