Oil Pan, Upper Section

Oil Pan, Upper Section

Special tools, testers and auxiliary items required

• Assembly Tool (T10118)

• Testing tool for Brake Wear (VW 136)

• Torque Wrench (V.A.G 1331)

• Hand drill with plastic brush attachment

• Protective eyewear

• Silicone sealant, refer to the electronic parts catalog ETKA

Removing

- Remove the transmission.

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

- Remove the rear sealing flange. Refer to => [ Transmission-Side Sealing Flange ] Transmission-Side Sealing Flange.

- Remove the oil pump. Refer to => [ Oil Pump ] Oil Pump.

- Disconnect the connector - 1 -.






- Remove the bolts - arrows -.







Risk of injury. When removing the oil pan upper section, the chain tensioner spring for the oil pump motor will jump from the oil pan upper section to the lower timing chain cover. When removing the oil pan upper section, do not reach between the section and the lower timing chain cover.

- Remove the bolts - 1 through 13 - and the upper section of the oil pan.







First pry the upper section oil pan out on the transmission side. When prying out, be careful not to bend the timing chain cover.

Installing

• Tightening specifications, refer to => [ Oil Pan and Oil Pump Overview ] Oil Pan and Oil Pump Overview.

• Silicone sealant, refer to the electronic parts catalog ETKA

• Note the expiration date of the silicone sealant.

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

• Replace the bolts which are being tightened with an additional turn.

• Replace sealing rings, seals and self-locking nuts.

- Mount the (T10118) and pull the spring in the oil pump drive chain tensioner in the direction of the - arrow -.






- Secure the spring by inserting the (VW 136) into the hole in the guide rail as illustrated.

- Remove sealant residue from cylinder block with a flat scraper.


Risk of eye injury.

• Wear safety glasses.

- Remove any remaining sealant on oil pan upper section using for example, a rotating plastic brush.






• See if the timing chain cover is deformed. Then mount the top section of the oil pan without any sealant and check the gap between the cover and the top section. If deformation is found and the cover cannot be aligned, replace the cover after installing the oil pan upper section.

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

- Make sure the oil passages in the upper section of the oil pan and in the cylinder crankcase clean.

- Cut the tube nozzle at the front marking (diameter is approximately 3 mm).






- Apply silicone sealant to clean sealing surface of the upper oil pan section as shown in the illustration - arrows -.






• Sealant bead thickness: 2 to 3 mm.

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

• The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

• On the transmission side, the upper section of the oil pan and the crankcase must align.

- Position the upper section of the oil pan immediately and tighten the bolts, tightening sequence => [ Oil Pan, Upper Section, Tightening
Sequence ] Oil Pan and Oil Pump Overview.

- Install the bolts - arrows -. Tightening specifications => [ (Item 13) Bolt ] Timing Chain Cover Overview.






- Remove the (VW 136) from the guide rail - arrow -. The spring now returns to the installed position.






- Install the rear sealing flange. Refer to => [ Transmission-Side Sealing Flange ] Transmission-Side Sealing Flange.

- Install the oil pump. Refer to => [ Oil Pump ] Oil Pump.

- Replace the baffle plate.

The rest of the assembly is basically a reverse of the disassembling sequence.

- Fill the engine oil and check the level.