Upper Oil Pan

Upper Oil Pan

Special tools, testers and auxiliary items required

• Adapter Plates (2036/1)

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

• Locking Pin (T10115)

• 3 M8 x 20 Bolts and 3 Washers

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Silicone Sealant (D 174 003 A2)

Removing

- Remove the adjuster and sprocket from the camshafts. Refer to => [ Valve Timing, Adjusting ] Valve Timing, Adjusting.

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

- Tension the chain tensioner - 1 - and secure it using the locking pin (T10115).






- Remove the 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 oil intake pipe.






- Remove the bolts - 1 -.

- Pry the upper oil pan from the cylinder block using a suitable screwdriver - A - at the areas shown.






B Crankshaft bearing cap 6
C Crankshaft bearing cap 1

Installing


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

- Remove any sealant residue from the cylinder block using for example, a rotating plastic brush.


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 sealant tube nozzle at the front mark (nozzle diameter: approximately 1 mm).






Note the shelf life date.

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

- Apply sealant beads - 1, 2 and 3 - to the clean sealing surfaces of the upper oil pan as shown.






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

- Position the upper oil pan on 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 the - arrows -.






- Loosen the bolts again slightly.

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

- Press the upper oil pan tightly against the adapter plates (2036/1) and tighten the bolts hand tight.

- Install the remaining upper oil pan bolts and tighten them hand tight.

Make sure that upper oil pan makes contact with the adapter plates (2036/1).

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

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






- Secure the oil intake pipe - 1 - and the bracket - 4 - with the bolts - 2 and 3 -.

- Install the guide rail - 2 -, relieve tension on the chain tensioner - 1 - and pull out the locking pin (T10115).






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

The rest of the installation follows the reverse of the removal procedure. 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 locking pin (T40069) from the rear of the cylinder block and install the locking bolt.

• Fill the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.

Tightening Specifications