Upper Oil Pan

Upper Oil Pan

Special tools, testers and auxiliary items required

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

• Locking Pin (T10115)

• Adapter Plates (2036/1)

• Three M8 x 20 Bolts and Washers

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Silicone Sealant (D 174 003 A2)

Removing

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

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

- Tension the chain tensioner - 1 - and secure it using the locking pin (T10115).






- Remove the guide rail - 2 -.

- Remove the belt pulley side sealing flange. Refer to => [ Sealing Flange, Belt Pulley Side ] Service and Repair.

- 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 crankshaft
C Bearing cap 1, for crankshaft

Installing

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

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

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 sealant tube nozzle at the front mark (nozzle diameter: approximately 1 mm).






Note the 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 illustrated.






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

- Position the upper oil pan on 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 the - arrows -.






- Loosen the bolts again slightly.

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

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

- Install the remaining bolts and tighten them by hand.

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

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

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






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

- Install guide rail - 2 -, relieve tension on the chain tensioner - 1 - and pull out the locking pin (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 locking pin (T40069) from the cylinder block and install the plug.

• Fill the coolant. Refer to => [ Draining and Filling ] Service and Repair.

Tightening Specifications