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)
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 ] Sealing Flange, Transmission Side.
- Remove the front right wheel housing liner..
- Remove the bolts - arrows -.
- Remove the charge air pipe by lifting the clamps - 1 and 2 -.
- Remove the bolt - 1 -
- Disconnect the wiring bracket mount next to the after-run coolant pump (V51) from the upper oil pan.
- Remove the bolts - arrows -.
Risk of injury. When removing the up 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 supper oil pan and the lower timing chain cover.
- Remove the bolts - 1 through 14 - and pry out the upper oil pan.
First pry the upper oil pan out on the transmission side. When prying out, be careful not to bend the timing chain cover.
Installing
• Tightening specifications, refer to => [ Oil Pan and Pump Overview ] Oil Pan and Pump Overview.
• Note the expiration date of the silicone sealant.
• The upper oil pan must be installed within 5 minutes after application of silicone sealant.
- Using (T10118), pull the spring in the oil pump drive chain tensioner in the direction of the - arrow -.
- Secure the spring by inserting (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 safety glasses.
- Remove the remaining sealant from the upper oil pan and from the lower timing chain cover, for example with a rotating plastic brush.
• See if the timing chain cover is deformed. Mount the upper oil pan without any sealant and check the gap between the cover and the oil pan. If deformation is found and the cover cannot be aligned, replace the cover after installing the upper oil pan.
- Clean sealing surfaces, 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 tube nozzle at the front mark (nozzle diameter approximately 3 mm).
- Apply the silicone sealant (D 174 003 A2) to the clean sealing surface of the upper oil pan as shown - arrows -.
• Sealant bead thickness: 2 to 3 mm
• The upper oil pan must be installed within 5 minutes after application of silicone sealant.
• The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.
• On the transmission side, the upper oil pan and the crankcase must align.
- Immediately mount the upper oil pan and tighten the bolts - 1 through 14 - in three passes as follows:
1 - Tighten the bolts hand-tight
2 - Tighten the bolts to 15 Nm
3 - Tighten the bolts an additional 90 degrees (1/4) turn
- Install the bolts - arrows -. Tightening specification, refer to => [ Lower Timing Chain Cover Bolt Tightening
Sequence and Specification ] Timing Chain Cover Assembly Overview.
- Remove the (VW 136) from the guide rail - arrow -. The spring now returns to the installed position.
The rest of the installation is basically a reverse of the removal sequence.