Upper Oil Pan

Upper Oil Pan

Special tools, testers and auxiliary items required

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

• Locking Pin (T10115)

• Adapter Plates (2036/1)

• 3 M8 x 20 Bolts and 3 Washers

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Silicone Sealant (D 174 003 A2)

Removing

- Loosen the adjuster and sprocket on the camshafts, refer to => [ Valve Timing, Adjusting ] Valve Timing, Adjusting.

- Remove the control housing cover. Refer to => [ Control Housing Cover ] 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. 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 oil intake pipe bolts - 2 and 4 - and intake pipe.






- Remove the bolts - 1 -.

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






B Crankshaft bearing cap 6
C Crankshaft bearing cap 1

Installing


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

- Remove the remainder of sealant from the upper oil pan and cylinder block, for example, using 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 sealant.

- Apply the sealant beads - 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 the - arrows -.






- Loosen the bolts again slightly.

- Install the adapter plates (2036/1) from the adjustable rod (2036) to the cylinder block as shown.

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

- Install the remaining bolts and tighten them hand tight.

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

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

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






- Install the oil intake pipe - 1 - , the bracket - 4 - and the bolts - 2 and 3 -.

- Install the guide rail - 2 -, relieve the tension on the chain tensioner - 1 - and remove 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 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 locking pin (T40069) from the rear of the cylinder block and install the locking bolt.

- Fill the coolant. Refer to the following:

• Jetta from MY 11, refer to => [ Draining and Filling ] Procedures.

Tightening Specifications