Oil Pan

Oil Pan

Special tools, testers and auxiliary items required

• Engine Support Bridge (10-222 A)

• Socket (3249) or (T10058 )

• Old Oil Collecting And Extracting Device (V.A.G 1782 )

• Shop Crane (VAS 6100)

• Insert Pad For Front Fender (T40045)

• Lifting Tackle (2024 A)

• Hand drill with plastic brush attachment

• Protective eyewear

Removing

• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

- Open the quick-release fasteners - arrows - and remove the engine cover.





- Remove right cover - 1 - in the engine compartment, if equipped.





- Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) from the air guide.

- Remove bolts - arrows -.





- Remove air duct - 2 -.

• Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the ribbed belt under operating conditions.

- Move the tensioning element in direction of - arrow - to release the tension on the ribbed belt.





- Remove the ribbed belt from the generator belt drive pulley.

- Release the tension on the tensioning element.

- Remove ribbed belt completely.

• If the ribbed belt cannot be removed from the pulley, loosen the tensioner bolts a few turns.

- Remove hood seal at bolted fender flanges.

- To avoid damaging bolted fender flanges with Engine Support Bridge (10-222 A), insert Fender Insert Pads (T40045) on both sides between bolted fender flanges and web plate beneath.





- Position Engine Support Bridge (10-222 A) onto bolted flange of fenders.





- Remove Lifting Tackle (2024 A) eyes.





- Insert bolt - 1 - in the center bore of engine sling again and secure with a cotter pin.

- Engage Lifting Tackle (2024 A) screws at Engine Support Bridge (10-222 A) spindle.

- Hook Engine Sling (2024 A) into sling clamps at front and rear of engine.





CAUTION!
Lifting hooks and alignment pins on lifting tackle must be secured with securing pins - arrows -.

- Pretension the engine with the engine support bridge spindle but do not lift.

- Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.





- Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.

- Remove bracket for noise insulation - arrows -.





- Place Old Oil Collecting and Extracting Device ( V.A.G 1782) under engine and drain engine oil.

- Remove the oil return line form the oil pan while removing the bolts - arrows -.





- Disconnect electrical harness connector - arrow - at Oil Level Thermal Sensor (G266).





- Remove bracket for refrigerant line on oil pan - arrow -.





- Separate connector - 1 - for wiring to air conditioning compressor clutch solenoid.





CAUTION!
The air conditioning refrigerant circuit must not be opened.

- Remove air conditioning compressor from bracket - arrows -.

• To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

- Hang up the air conditioning compressor with attached lines on the vehicle.

- Remove bolts - arrows - and the torque support.





- Unclip the lower actuator rod for the Left Front Level Control System Sensor on the transverse link - arrow -.





- Remove stabilizer mount bolts - 1 - and - 2 -.





- Cut through the cable ties - arrows -, open the starter harness retainer and take the electrical harness out.





- Support the subframe with the Workshop Crane ( VAS 6100) or (V.A.G 1202 A).





- Remove lower nut - 3 - on engine mount.





- Remove bolts - 4 - and - 5 - on the engine mount bracket.

- Remove front bolt - 1 - for subframe and remove the engine mount bracket - 2 -.

- Repeat work procedure on opposite side of the vehicle.

- Slowly lower the subframe with the Workshop Crane (VAS 6100) or (V.A.G 1202 A).





- Lift the engine slightly upward using the spindle from the Engine Support Bridge (10-222 A), paying attention to the clearance of the shift linkage and exhaust system.





- Remove bolts - arrows - for transmission/oil pan.





- Remove M10 bolts - arrows -.





- Loosen bolts - 1 to 18 - in a diagonal sequence.

• Remove both rear oil pan bolts - 1 - and - 2 - using Multi-Point Socket (3249) or (T10058) ; on manual transmission vehicles turn the dual mass flywheel - 3 - until the cut-out - arrow - aligns with the bolt.





- Remove all the bolts and then remove the oil pan, if necessary lightly tap the pan with a rubber hammer to loosen it.

Installing





Installation is in reverse order of removal, note the following:

• Always replace gaskets and seals.

• During installation, all cable ties must be re-installed at the same location.

- Carefully remove any remaining sealant on the cylinder block when removing the oil baffle.

- Remove sealant residue on oil pan, e.g. with a rotating plastic brush.

CAUTION!
Wear safety glasses.

- Clean sealing surfaces, they must be free of oil and grease.

- Cut tube nozzle at front marking (nozzle dia. approximately 2 mm).





- Apply sealant bead as illustrated to clean sealing surface of oil pan.

• Thickness of sealant bead: 2 to 3 mm.

• Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer.

• Being especially careful, apply a bead of sealant around the sealing flange - arrows -.





• The oil pan must be installed within 5 minutes of being applied with sealant.

- Install oil pan immediately and tighten the bolts in the described sequence:





- Pre-tighten bolts - 1 to 18 - in diagonal sequence to 5 Nm.

- Tighten oil pan/transmission bolts to 45 Nm.

- Tighten bolts M10 - arrows - to 40 Nm.

- Tighten bolts - 1 to 18 - in a diagonal sequence to 15 Nm using a torque wrench.

• When installing the oil pan - 3 - on a removed engine, make sure that the flywheel end of the oil pan is aligned flush with the intermediate plate - 1 -, therefore the oil pan must extend beyond the cylinder block - 2 - by the dimension - a - 0.8 mm.





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

- Install subframe.

- Install stabilizer.

- Install A/C compressor.

- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Add engine oil and check oil level.

Tightening Specifications