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) (V.A.G 1331)
• Silicone Sealant (D 174 003 A2)
• Flat Scraper
• Hand Drill with Plastic Brush Attachment
• Protective Eyewear
Removing
- Remove the transmission.
- 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 right front wheel housing liner.
- Remove the bolts - arrows -.
- Lift the clamps - 1 and 2 - and remove the charge air pipe.
- Remove the bolt - 1 -
- Remove the wiring harness bracket next to the after-run coolant pump (V51) from the upper oil pan.
To prevent leaks in the future, do not bend the lower timing chain cover and do not reach between the mounting points.
- Remove the bolts - arrows -.
Risk of injury. When removing the upper oil pan, the chain tensioner spring for the oil pump motor 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.
First, pry the upper oil pan out on the transmission side. When prying out, be careful not to bend the timing chain cover.
- Remove the bolts in sequence - 14 through 1 - and pry off the upper oil pan.
Installing
Tightening specifications, refer to => [ Oil Pan and Pump Overview ] Oil Pan and Pump Overview.
• The sealing surfaces must be completely free of oil and grease.
• Note the expiration date of the silicone sealant.
• The upper oil pan must be installed within 5 minutes after applying the silicone sealant.
- Install the assembly tool (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 testing tool for brake wear (VW 136) into the hole in the guide rail, as illustrated.
- Remove the sealant residue from the cylinder block with a flat scraper.
Risk of eye injury.
• Wear protective eyewear.
- Remove the remaining sealant from the upper oil pan and the lower timing chain cover, for example, with a rotating plastic brush.
• See if the timing chain cover is deformed. Then mount the upper oil pan without any sealant and check the gap between the cover and the upper pan. If deformation is found and the cover cannot be aligned, replace the cover after installing the upper oil pan.
- Clean the sealing surfaces, 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 sealant tube nozzle at the front mark (nozzle diameter: approximately 0.12 in).
- Apply the silicone sealant to the clean sealing surface of the upper oil pan - arrows -.
• Thickness of sealant bead: 2 to 3 mm.
• The upper oil pan must be installed within 5 minutes after applying the silicone sealant.
• The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake pipe.
• On the transmission side, the upper oil pan and the crankcase must align.
- Immediately install the upper oil pan and tighten the bolts in sequence - 1 through 14 - in three passes as follows:
1 - Tighten the bolts by hand
2 - Tighten the bolts to 15 Nm
3 - Tighten the bolts an additional 90° (1/4) turn
- Install the bolts - arrows -. Tightening specification, refer to => [ Lower Timing Chain Cover Bolt Tightening Sequence and Specification ] Timing Chain Covers Overview.
- Remove the testing tool for brake wear (VW 136) from the guide rail - arrow -. The spring now returns to the installed position.
Further installation is in the reverse order of removal.