Upper Oil Pan

Upper Oil Pan

Special tools, testers and auxiliary items required

• Adjustable rod (2036)

• Torque wrench 5-50 Nm (VAG 1331)

• Locking pin (T10115)

• 3 M8 x 20 bolts with washers

• Hand drill with plastic brush attachment

• Protective eyewear

• Silicone sealant (D 174 003 A2)

Removing

- Loosen the camshaft gears. Refer to --> [ Valve Timing, Adjusting ] Adjustments.

- Remove the control housing cover. Refer to --> [ Control Housing Cover ] Service and Repair.

- Tension the oil pump drive chain tensioner - 1 - and secure it using the (T10115).





- Remove guide rail - 2 -.

- Remove the sealing flange, belt pulley side. Refer to --> [ Sealing Flange, Belt Pulley Side ] Service and Repair.

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

- Remove the bolts - 2 - and - 4 - and remove the intake pipe.





- Remove bolts - 1 -.

- Pry off the upper oil pan from the cylinder block at the designated points using a suitable screwdriver - A -.





B Bearing cap 6 for the crankshaft
C Bearing cap 1 for the crankshaft

Installing

CAUTION!
To prevent injuries from shavings, wear protective goggles and protective clothing.

- Remove the remainder of sealant from the upper oil pan and cylinder block e.g. using a rotating plastic brush.

CAUTION!
Make sure that no sealant residue enters the engine.

- Clean the sealing surfaces so they are completely free of any oil or grease.

- Cut the tube nozzle at the front marking (diameter of nozzle approximately 1 mm).





Note the shelf life date.

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

- Apply the sealant bead - 1 -, - 2 - and - 3 - as shown onto the clean sealing surface of the upper oil pan.





• The sealant bead must be 1.5 to 2.0 mm thick.

- Place the upper oil pan onto the cylinder block and align it on the transmission side.

- Install 2 bolts each at the front and rear hand tight.

- Wipe off any excess sealant in the area of - arrows -.





- Loosen the bolts again slightly.

- Install the (2036/1) from the (2036) onto the cylinder block as shown.

- Press the upper oil pan firmly onto the (2036/1) and tighten the bolts again hand tight.

- Install the remaining bolts and tighten by hand.

Make sure that the upper oil pan makes contact on the (2036/1).

- Tighten all bolts in a diagonal sequence from the inside working toward the outside.

- Install a new seal - 5 - into the oil pump - 6 -.





- Install the intake pipe - 1 - with bolts - 2 - and - 3 - as well as bracket - 4 -.

- Install the guide rail - 2 -, relieve the tension on the oil pump drive chain tensioner - 1 - and remove the (T10115).





- Adjust the valve timing. Refer to --> [ Valve Timing, Adjusting ] Adjustments.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

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

• Remove the (T40069) from the cylinder block and install the locking bolt. Tightening specification: 30 Nm.

• Fill the cooling system. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.

Tightening Specifications