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 (VAG 1331)

• Silicone sealant (D 174 003 A2)

• Flat scraper

• Hand drill with plastic brush attachment

• Protective eyewear

Removing

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

- Remove the sealing flange, refer to --> [ Sealing Flange ] Sealing Flange.

- Remove the charge air pipe bolts - arrows -.





- Remove the charge air pipe by lifting the clamps - 1 and 2 -.

- Remove the charge air pipe bolt - 1) -





- Remove the wiring harness bracket next to the after run coolant pump from the upper oil pan.

CAUTION!
To prevent leaks in the future, do not bend the lower timing chain cover and do not reach between the mounting points.

- Remove the lower timing chain cover bolts - 14 and 15 -.





DANGER!
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 - 14 through 1 - and remove the upper oil pan.





Installing

• Tightening sequence and specification, refer to --> [ Upper Oil Pan Bolt Tightening Sequence and Specification ] Oil Pan and Pump Assembly Overview.

• Use silicone sealant (D 174 003 A2).

• Sealing surfaces must be completely free of oil and grease.

• Note the expiration date of the silicone sealant (D 174 003 A2).

• The upper oil pan must be installed within 5 minutes after applying the silicone sealant (D 174 003 A2).

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





- Secure the spring by inserting the (VW 136) into the 2.2 mm hole, as shown in the illustration.

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

CAUTION!
Wear safety glasses.

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





- Clean the sealing surfaces, they 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 tube nozzle at the front marking (diameter of nozzle approximately 3 mm).





- Apply the silicone sealant (D 174 003 A2) to 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 applying the silicone sealant (D 174 003 A2).

• The sealant bead must not be thicker than specified, otherwise excess sealant could get into the oil pan and clog the strainer in the suction pipe of the oil pump.

• Note the expiration date of the silicone sealant (D 174 003 A2).

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

- Position the upper oil pan immediately and tighten the bolts.

• Tightening sequence and specification, refer to --> [ Upper Oil Pan Bolt Tightening Sequence and Specification ] Oil Pan and Pump Assembly Overview.

- Tighten the lower timing chain cover bolts - 14 and 15 -:





• Tightening sequence and specification, refer to --> [ Lower Timing Chain Cover Bolt Tightening Sequence and Specification ] Timing Chain Covers Assembly Overview.

• After installing the lower oil pan, the sealant must dry for approximately 30 minutes. Only after then may the engine oil be added.

Install in reverse order of removal. When doing this note the following:

- Fill the engine with oil.

- Check the oil level. Refer to --> [ Oil Level, Checking ] Testing and Inspection.