Upper Oil Pan

Upper Oil Pan

Special tools, testers and auxiliary items required

• Testing Tool for Brake Wear (VW 136)

• Assembly Tool (T10118)

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

• Silicone Sealant (D 174 003 A2)

Removing

- Remove the transmission, refer to one of the following:

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

- Remove the sealing flange. Refer to => [ Sealing Flange, Transmission Side ] Service and Repair.

- Remove the right front wheel housing liner.

- Remove the bolts - arrows -.






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

- Remove the bolt - 1 -






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

- Remove the bolts - arrows -.







Risk of injury. When removing the upper oil pan, the chain tensioner spring for the oil pump 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.







First, pry the upper 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.

• Note the expiration date of the silicone sealant.

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

- Using the assembly tool (T10118) , pull the spring in the oil pump drive chain tensioner in the - direction of the arrow -.






- Secure the spring by inserting the testing tool for brake wear (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 protective eyewear.

- Remove the remaining sealant on the upper oil pan and lower timing chain cover, for example with a rotating plastic brush.






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

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

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

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






- Apply the silicone sealant (D 174 003 A2) on the clean sealing surface of the upper oil pan as shown - arrows -.






• Thickness of sealant bead: 2 to 3 mm

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

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

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

- Immediately install the upper oil pan and tighten the bolts - 1 through 14 - in three passes as follows:






1 - Tighten the bolts by hand

2 - Tighten the bolts to 15 Nm

3 - Tighten the bolts an additional 90° (1/4) turn

- Install the bolts - arrows -. Tightening specification, refer to => [ Lower Timing Chain Cover Bolt Tightening Sequence ] Timing Chain Covers Overview.






- Remove the testing tool for brake wear (VW 136) from the guide rail - arrow -. The spring now returns to the installed position.






The rest of the installation is basically a reverse of the removal sequence.