Upper Oil Pan

Upper Oil Pan

Special tools, testers and auxiliary items required

• Assembly Tool (T10118)

• Brake Pad Wear Indicator Testing Tool (VW 136)

• Torque Wrench 5-50 Nm (V.A.G 1331)

• Hand drill with plastic brush attachment

• Protective goggles

• Silicone sealant, refer to the Electronic Parts Catalog (ETKA)

Removing

- Remove the transmission.

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

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

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

- Remove the right front wheel housing liner.

- Remove the bolts - arrows -.






- Lift the clamps - 1 and 2 - and remove the air guide pipe.

- Remove the bolt - 1 -






- Disconnect the wiring bracket mount next to the after-run coolant pump (V51) from the upper oil pan.

- Disconnect the connector - 1 -.






- Remove the bolts - arrows -.






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

- Remove the bolts - 1 through 14 - and pry out the upper oil pan.






• There may be 13 bolts installed, depending on the version.

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

Installing

• For the correct 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.

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

Danger of eye injury.

• Wear protective goggles.

- Remove the sealant residue on the upper oil pan, for example using a rotating plastic brush.






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

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






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






The lubrication system could be plugged with excess sealant.

• Do not apply sealant bead thicker than indicated.

• Thickness of sealant bead: 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.

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

- Install the bolts - arrows -. Tightening specification, refer to => [ (Item 13) Bolt ] Timing Chain Guard and Camshaft Adjustment Valve 1 (N205) Overview.






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






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

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

- Replace the baffle plate.

- Install the lower timing chain cover. Refer to => [ Lower Timing Chain Cover ] Lower Timing Chain Cover.

Assemble in reverse order of disassembly.