Upper Oil Pan

Upper Oil Pan

Special tools, testers and auxiliary items required

• Assembly Tool (T10118)

• Locking Tool (T40265)

• Silicone sealant (D 174 003 A2)

Removing

- Remove the transmission. Refer to one of the following:

=> Direct Shift Gearbox Removal and Installation.

=> Manual Transmission Removal and Installation.

=> Automatic Transmission Removal and Installation.

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

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

- Remove the front right 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 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 pan and the lower timing chain cover.

- Remove the upper oil pan bolts - 1 through 14 - and pry off the upper pan.






First, pry the upper oil pan off on the transmission side. When prying off, be careful not to bend the timing chain cover.

Installing

• Tightening specification, refer to => [ Oil Pan/Oil Pump Overview ] Oil Pan/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.

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

Danger of eye injury.

• Wear protective eye wear.

- Remove the remaining sealant on the upper and the lower timing chain covers, for example using a rotating plastic brush.






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

- 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 clean.

- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 0.12 in).






The lubrication system could be plugged with excess sealant. Do not apply the sealant bead thicker than indicated.

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






- In addition, apply a small amount of silicone sealant (D 174 003 A2) between the cylinder block and the timing chain cover - 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 the excess sealant could enter the oil pan and clog the oil suction pipe.

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

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






1 - Tighten the bolts hand tight.

2 - Tighten the bolts to 15 Nm.

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

- Install the bolts - arrows -.

Tightening sequence for the cover with 15 bolts, refer to => [ Lower Timing Chain Cover Bolt Tightening Sequence, with 15 Bolts ] Timing Chain Cover Overview.

Tightening sequence for the cover with 8 bolts, refer to => [ Lower Timing Chain Cover Bolt Tightening Sequence, with 8 Bolts ] Timing Chain Cover Overview.






Further installation is in the reverse order of removal.